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As we build our knowledge database, we want to share with you all that we know — from design and engineering tips, to manufacturing hardware — , in our mission to #HelpMakersMake.
Here is an article written by our engineering team that will guide you on the most common material choices that our customers have to make. The material choices made when you prototype something are influenced by the end application of the part. Some examples are whether the part is a form-fit prototype, production prototype or a feasibility prototype.
1.0 Metals
1.1 Aluminium
1.1.1 Al 6061
Al 6061 is the most common type of Aluminum that is used for both prototyping and precision machining application(s) for mass manufacturing. Perhaps one of the most versatile materials available thanks to it’s impressive strength-to-weight ratio (Ultimate Tensile Strength of 290 MPa), but more prominently, ease of welding over other types of Aluminum. As a result of it being easily machinable, it is widely used as a construction material, most commonly in the manufacture of automotive parts, architectural components and other miscellaneous components that are used in a variety of day to day items. As Al 6061 extrusions are widely available, many structures make use of lathed and/or cut extrusions welded into place. This is a relatively cost effective means of manufacturing an entire structure without high-cost methods such as machining.
1.1.2 Al 7075
The main difference between Al 6061 and Al 7075 is the tremendous increase in tensile strength. Al 7075 has one of the highest strengths of commercially available forms of Aluminum (Ultimate Tensile Strength of 572 MPa). Albeit it’s low weldability, it’s low density and high strength makes it ideal for high performance components where strength is critical but weight savings are also prioritized. Therefore, Al 7075 is widely used in the aerospace industry, defense applications and many mechanical components which undergo high stresses such as gears, shafts and worm gears.
1.1.3 Al 5052
Al 5052 exhibits a much higher workability over Al 6061 allowing it to be formed into intricate shapes. It also has a high fatigue strength with…
