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PRO TO CAST.PROTOTYPES &
DIE CASTING.

Our first-class die-casting solutions make us your system supplier for assemblies made of cast parts of all kinds.

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Die-Casting

Always the right solution
for your requirements.

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Prototypes

From design and construction to the production of complex prototypes.

We produce individual products for you from different manufacturing processes and this in an economical and high-quality way.

We are able to manufacture these as milled, cast or lasered variants.

We are also happy to work for you in a small quantity range from 50 pieces.

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Prototype castings
CNC-Milled
Prototypes

Manufacturing

We manufacture high-precision machine components with the highest perfection and a comprehensive range of machinery.

In addition to machining on CNC machines, our services also include toolmaking, surface finishing and metalworking, the manufacture of aluminium profiles and the assembly of components.

With us, you benefit from a competent contact person for comprehensive service for your product.

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Company

We are a DIN 9001:2015 certified company that understands itself as a system supplier for individual parts and assemblies. We supply our customers worldwide from our branches in Germany, Turkey and China.

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Industries

As a system supplier for individual parts and assemblies, we support you in these industries right from the development phase:

Automotive

Within the automotive industry, we supply our customers with designs, prototypes and products that can be found throughout the vehicle.

Lighting industry

We offer our customers complete assemblies or filigree individual parts with high demands on functionality, form and design.

Automation industry

We support the automation industry with the production of various prototypes using die casting or machining.

Electronics industry

Due to the variety of shapes of die-cast products, they can be found in a wide range of products from the electronics industry.

Mechanical Engineering

Our products are used in various areas, such as power engines, working machines, machine tools, conveyor systems, automotive engineering and aerospace technology.

Medical Technology

The far-reaching national, supranational and international standardization of our products offers the best conditions for medical applications.

Transport

Due to the lightweight construction potential of castings, many of our products are suitable for this industry.

Automotive
Lighting industry
Automation industry
Electronics industry
Mechanical Engineering
Medical Technology
Transport

News

We always keep you informed about news from the industry and about our company.

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Career at Protocast

You are a pupil or student and would like to prove yourself in the working world? You would like to develop yourself and are looking for an interesting job in the commercial sector? Then apply to us and get the opportunity to take on responsible positions.

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Industrial Agencies

For the purpose of expanding our distribution network both, nationwide and in Europe, we are looking for industrial or commercial agencies that will primarily fulfil their tasks with the utmost care in terms of customer acquisition and support:

Further information

Innovative die casting and prototype construction at Protocast

With a combination of experience as well as the necessary inventive spirit, we can create maximum added value for each of our customers time and time again. Our goal is to develop first-class prototypes and die-cast products to help our customers advance economically and to inspire them in their development.

Are you interested in prototypes or die casting? Then you can get comprehensive information here. If you have any further questions, please contact us directly.

Prototyping - what is that?

Prototyping is becoming more and more the center of our everyday life.

The production of prototypes – i.e. prototyping – always pursues the goal of visualizing initial ideas, testing aspects of a solution or testing a preliminary result. Prototypes support the iterative process of model creation in the search for problem solutions. In other words, prototypes enable a step-by-step approach to the actual solution.

Prototypes are therefore a relevant component in the development of new innovations. Used correctly, prototypes protect against risks, generate trust, achieve participation and arouse enthusiasm.

Prototyping can be used to obtain quick feedback from the target groups and thus to find out at an early stage whether the product (or even service) is actually what future users really need and demand, even in a first version.

Like the industry in general, prototyping processes are in a continuous state of change. More and more must be produced in even shorter time and at the best possible conditions. What today is considered an innovative solution for the production of a prototype may already be outdated tomorrow and replaced by new technologies. Too strong is the current competition here, which constantly requires new solutions in order to remain successful in the long term as part of it. Here we have been able to secure decisive advantages in recent years through modern, advanced technologies.

What advantages does prototype construction offer?

In the last few years we have been able to make a name for ourselves in the field of prototyping. Whether the production of prototypes by die casting, 3D printing or by using many other proven methods – with our innovative prototypes and equally high-quality production methods for prototype construction, many customers have already been inspired by the advantages of prototyping. In addition, all of the processes we offer guarantee highly economical prototype production. The result is a highly precise prototype, which also has optimal technical and haptic properties.

Today, prototypes are indispensable in the industrial sector – especially in manufacturing industrial companies. Even if the end customer may not even see the prototype himself, a prototype is an essential element in the production of a product or in preparation for series production.

But not all prototypes are the same. Depending on the application, it makes sense to use specific manufacturing solutions for prototype construction. In this way, the prototype can be optimally adapted to the specific requirements of the respective application.

Investment casting prototype construction

By means of investment casting, high-quality castings made of steel and aluminum can be realized quickly and economically – which in turn can be used to produce high-quality and highly economical prototypes.

The proven rapid manufacturing process is used in particular when a comparatively less time-consuming production of metallic prototypes is required.

Even small series of five to 20 pieces can be realized in high quality castings.

Investment casting – what is that?

In investment casting, the master pattern is first duplicated in investment casting wax. Then the lost pattern is made of plastic in PMMA, mounted on a casting screw and finally cast in plaster.

Then the lost pattern is burnt out in the furnace and the resulting cavity is filled with liquid metal. The differential pressure method is used here.

Advantages of investment casting products

  • good mechanical properties
  • more cost-effective than other processes (laser)
  • high level of detail of the prototype
  • Sand casting prototype construction

It is also possible to produce high-quality prototypes using sand casting.

This process produces economical workpieces for the customer, which meet specific requirements and are also cost-effective to produce.

This is also a particularly sustainable process, as the sand can be recycled after use and processed into new shapes.

Sand casting – what is it?

Sand casting – also known as sand moulding – is a casting process for metal and other materials. In this process, sand moulds are used to produce aluminium or magnesium workpieces.

In sand casting, for example, a foundry pattern is moulded in sand, then removed and the resulting cavity is finally filled with the molten material.

Advantages of sand casting products

  • good mechanical properties
  • complicated geometries
  • Material cross sections
  • Sustainable

Rapid Prototyping – what is that?

Rapid Prototyping means translated ‘fast model making’. The name is program. Rapid Prototyping is an umbrella term for various processes aimed at the rapid production of sample components. These are implemented using previously developed design data.

Rapid prototyping thus aims at a fast and uncomplicated prototype construction. For this purpose we offer you a range of proven solutions and processes. So for each application there should be a suitable method for the implementation of high-quality prototypes.

A rapidly growing industry requires the ever faster production of prototypes. New innovations must be implemented and tested within the shortest possible time in order to prevail against the numerous competitors and to decisively shape the market.

Nearly all modern methods of prototype production aim to guarantee a fast, uncomplicated, and at the same time cost-effective prototype production and can therefore be called solutions of “Rapid Prototyping”.

Digital prototyping – what is that?

Digital prototyping generally describes a procedure in technical development. Thus, this procedure also aims to shorten the development time of new products and also to reduce the costs of development.

In digital prototyping, virtual prototypes are implemented which can then be tested digitally for their functionality.

The basis for digital prototyping is a 3D CAD model of the product. This model can then be used to test various aspects of a product using computational methods.

Advantages Digital Prototyping

  • lower costs than physical prototypes
  • Try out design variants
  • digital development (development network)
  • fast execution of tests
  • fast construction changes
What is die casting?

Die casting is a fully automated process in which molten metal is poured into steel molds and pressed. Various casting alloys such as aluminum, zinc or magnesium, which have a low melting point, are used for die casting. When carrying out our internal die-casting processes, we only use high-quality casting machines and equipment.

To ensure the first-class, consistent quality of our die-casting products, the casting moulds (these are the tools for die-casting) are specially and individually developed for each project based on individual customer requirements.

A great special feature of die-casting processes is the enormous cost saving, as many of the otherwise necessary finishing steps are omitted. In addition to narrow tolerance ranges, parts produced by die casting are characterized by high consistency and dimensional accuracy of all components.

In die casting processes, a distinction can be made between two different types of die casting machines – the cold and hot chamber process.

As the name already implies, significant differences between the two types of construction are especially in the feeding system, in which the liquid metal melt is made available for the actual casting production.

What possibilities do the various die casting processes and alloys offer?

In particular, die casting processes offer numerous advantages for series production in the manufacture of complex component geometries. In die casting, the liquid melt of zinc, magnesium or aluminum is pressed under high pressure into a permanent mold and finally solidified. This generally ensures that the castings have a high degree of dimensional accuracy with extremely high repeatability.

For the moderate melting temperatures (410-430°C) required for zinc die casting, the hot chamber process is used. With this production method, the pouring flask and plunger are permanently in the molten zinc.

At higher melting temperatures (from approx. 700 °C), however, it is necessary to use the cold chamber process. With this method, the pouring flasks and pouring containers are outside the melt, which must be dosed into the casting system for each casting.

The low melting temperatures in zinc die casting result in many other advantages such as short cycle times, long mould service life, low draft angles and near-net-shape castings. The properties of the zinc alloy itself also enable the production of first-class die-cast parts with the narrowest tolerances, as well as the casting of filigree and thin-walled components. Additional advantages are the excellent electrical and electromagnetic shielding properties of zinc.

Why you should trust Prototcast for die casting or prototyping!

There are many reasons to trust us in the field of die casting and prototyping!

  • Plants certified to ISO 9001:2015, ISO 50001:2011 and ISO 14001:2015
  • own construction as well as a mould and tool construction
  • Filling simulations and 3D prototype printing are part of our design consulting
  • Use of various aluminum, magnesium and zinc alloys
  • highly variable lot sizes – from small quantities to over 100,000 pieces
  • Hot and cold chamber die casting machines with locking forces of 20 – 80 and 125 – 510 tons respectively
  • Vacuum-assisted die casting possible if required
  • Initial sampling: PPF report according to VDA2; PPAP
  • most modern CNC machining centers for the complete machining of the parts
  • Surface treatment in the form of galvanizing, painting, powder coating or other coating processes
  • Cooperation with specialized and certified partners
  • Assembly of smaller modules
  • we use the latest technologies for quality assurance
  • Creation of CAD data
  • Analysis, development and implementation of safety, control and process control concepts, production data acquisition and evaluation, documentation
  • rapid prototyping
  • Development of first-class prototypes with properties as close as possible to series production
  • Many die casting alloys
  • Application specific manufacturing
  • Versatile possibilities Prototyping methods
  • Die casting process suitable for your application

From planning to installation

We realize your requirements.

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