Thanks to rapid prototyping, Barron provides customers with complete cast, machined and painted parts for time-sensitive programs and projects in as little as two weeks.

Rapid prototype pattern made in hours to days

From 3D model to SLA pattern to part in a matter of weeks

Integrating rapid prototyping into the product design and development process allows for design integrity evaluation of a precision investment cast part before going into full production and avoids complications resulting from incomplete or inadequate pre-production analysis of fit, form, and function. Experienced engineers recognize that inexpensive rapid prototyping is an opportunity to uncover component design flaws or make improvements prior to initiating the investment casting process. This preliminary step in the metal casting process ensures that the final production of the cast component will meet required specifications.

Rapid prototype pattern cast in metalShort Lead Times

Along with the potential for overall savings, rapid prototyping allows for shorter lead times. Bypassing the need for an aluminum tool cuts 2-8 weeks from typical investment casting lead time. In addition, sales and marketing teams can use rapid prototype parts to bypass the expense of full production and showcase specific models of proposed parts. .

 

Rapid Prototyping Process

Rapid prototype pattern and metal cast

The Barron Industries’ rapid prototyping process uses layered modeling techniques to create a precise model or pattern of the proposed investment casting component in resin or wax. Models or patterns are completed in as little as a few days. The model can then be used as-is or cast to desired specifications in a wide variety of alloys without the exepnse of additional tooling. With our Plex® manufacturing and enterprise resource planning (ERP) software, which eliminates errors and speeds up the rapid prototyping process, our expert engineers monitor the process and make informed decisions based on real-time data using four efficient and uncomplicated steps.

  1. Convert the math data or three-dimensional model (3D) into a solid model file and run solidification modeling.
  2. Build and cure the rapid prototype pattern, via a 3D printer (Projet) or Stereolithography (SLA) technology.
  3. Inspect the rapid prototype pattern to ensure it meets both surface finish and dimensional specifications.
  4. Manufacture and deliver the functional investment casting rapid prototype for validation.

This process assures the accuracy of every production casting.

We produce rapid prototype patterns using liquid resin or wax with advanced 3D printing equipment. Our advanced rapid prototyping pattern machines provide distinctive advantages to our customers and both rapid prototyping processes have the capability to produce in a matter of hours high quality and complex precision casting patterns that require no tooling.

Rapid prototyping takes virtual designs from computer-aided design (CAD) or animated modeling software and transforms them into functional investment casting patterns used in the metal casting process. A precise pattern is required since the quality of the pattern directly affects the successful production a of well-manufactured part. Because a computer program transforms the mathematical data directly into a prototype part, no tooling is involved. Simple or complex precision investment casting patterns can be made quickly with 3D rapid prototyping models. The models can then be tooled for production incorporating any design changes resulting from prototype testing. Barron Industries expertly covers every step of this critical process.

View recent rapid prototyping projects.

Quality First

Barron Industries’ experts utilize SOLIDCast® solidification modeling software to add operational intelligence throughout the manufacturing process. Continuous evaluation of tree and gating design, pouring and mold temperature, and part position ensure a high quality casting is produced the first time and every time — eliminating shrinkage or porosity in the casting. Rapid prototyping technicians have real-time access to detailed instructions and technical information at every point in the process to assure quality, create accountability, enhance continuous improvement, and provide transparency.

The quality of Barron Industries’ products and processes is further assured by our recent AS 9100:2009 (aerospace standard) quality certification. We also possess TS 16949:2009 and ISO 9001:2008 quality certifications. See our certifications.

Our customers’ investment cast parts are monitored for quality every step of the way—from concept to completion to delivery to your engineering or manufacturing facility.

More Than Rapid Prototyping

Barron Industries is able to provide concept-to-completion development of precision investment casting components. In addition to rapid prototyping, we offer customers comprehensive investment casting services that result in reduced lead times, enhanced accountability, minimized retooling and lower project costs.

For more information on how our rapid prototyping process can save you time and money, contact us or request a quote.

"We initially worked with Barron Industries on the 2002 Ford Thunderbird. Against an extremely tight deadline, they were able to create prototype parts in two materials so we could test and choose one. Then they reproduced the parts to meet an aggressive launch schedule. I believe when a company goes to the extreme to deliver for me, I return the favor with loyalty. Barron Industries is our investment casting partner."

- Satisfied Client

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