Automotive
Engine Block Prototype
Integrated forming with complex internal structures. 3DP sand mold + gravity casting. Delivered 3 prototype castings in 8 working days from CAD approval.
Prototyping Service
Rapid Prototype Casting — Functional Metal Parts in Days
Need a functional metal prototype fast? Send your CAD file and we print molds or wax patterns, pour metal, and deliver finished castings — all in 5-15 business days. Zero tooling. Unlimited design iterations. 7 alloy families. 31 years of RP casting expertise.
5-15
Business Days
$0
Tooling Cost
7
Alloy Families
30+
Years in RP Casting
30+ Years RP Casting
ISO 9001 Certified
Benchmark Parts Available
No Minimum Order
5-15 Day Delivery
Global Shipping
How It Works
From CAD to Casting in 5 Steps
Our integrated process eliminates the longest lead-time items in traditional prototyping — no pattern shop, no tooling fab, no waiting.
1
Upload CAD
Send your 3D model. Our engineers review for castability and recommend the optimal process within 24 hours.
2
3D Print Mold/Pattern
We print sand molds (3DP/SLS) or wax patterns (SLS) directly from your CAD — no tooling required.
3
Cast Metal
Pour your alloy using the optimal casting method — gravity, low-pressure, or precision investment casting.
4
Machine & Finish
CNC machining, heat treatment, and surface finishing to your specification.
5
Inspect & Ship
Full dimensional inspection, material certification, and global shipping. Ready for your testing.
Why Us
Why Engineers Choose 3DPTEK for Rapid Prototype Casting
Not all rapid casting services are equal. Here is what 31 years of RP casting expertise brings to your project.
31 Years in RP Casting
First commercialized SLS in China (1994). Pioneered rapid prototyping casting technologies longer than anyone.
Engineer-to-Engineer
Your project is reviewed by casting engineers, not salespeople. DFM feedback within 24 hours of file submission.
No Tooling. No MOQ.
One part or one hundred. Same process, same quality. Design iterations cost only machine time and materials.
Full Chain In-House
3D printing, casting, machining, inspection — all under one roof. No subcontractor delays or finger-pointing.
Materials
Materials & Casting Capabilities
Production-proven process parameters for every alloy we pour. 30+ material process formulations developed in-house.
Aluminum
A356, ZL101 — auto, aero, marine. 2 mm min wall via SLS wax.
Cast Iron
HT200, QT400 — engine blocks, machinery bases.
Cast Steel
ZG25-ZG45 — structural, heavy equipment.
Stainless
304, 316, 17-4PH — marine, chemical, food-grade.
High-Temp
Inconel 718, Hastelloy — turbine, aerospace.
Titanium
Ti6Al4V — aero, medical, high-performance.
Copper Alloys
Brass, bronze — electrical, marine, decorative.
Magnesium
AZ91D — lightweight auto, electronics.
Technology Choice
Two Technologies, One Service
We select the optimal 3D printing technology based on your part size, accuracy requirements, and alloy.
LARGE PARTS
3DP Sand Mold Printing
Binder Jetting bonds foundry sand layer-by-layer. Build volumes up to 4,000mm for oversized castings. Ideal for engine blocks, large housings, machinery components. 3DPTEK J1800, J2500, J4000 printers.
Max Size
4,000 mm
Accuracy
±0.3 mm
Surface
<Ra 25
HIGH PRECISION
SLS Wax Pattern Printing
Selective Laser Sintering produces precision wax patterns for investment casting. Superior surface finish (Ra 3.2-6.3µm) and complex thin-walled geometries. LaserCore-5300, LaserCore-6000 printers.
Max Size
1,050 mm
Min Wall
2 mm
Surface
Ra 3.2-6.3µm
Comparison
Rapid Prototype Casting vs. Traditional Prototyping Methods
When you need functional metal prototypes — not plastic look-alikes — see how rapid prototype casting compares to alternatives.
| Metric | Traditional Sand Casting | CNC Machining | 3DPTEK Rapid Prototype Casting |
|---|---|---|---|
| Lead Time | 4-12 Weeks | 1-4 Weeks | 5-15 Days |
| Tooling Cost | $1,000-$50,000+ | $0 | $0 |
| Internal Cavities | Yes | Limited | Unlimited |
| Thin Walls | 3-4 mm | 1 mm+ | 2 mm |
| Design Iteration | New Tooling Required | Re-Program CAM | Re-Print Mold |
| Material Options | Wide | Stock-Dependent | 7 Alloy Families |
Try Before You Buy
Affordable Benchmark Parts — See Quality Before You Commit
Send us your file or choose from our benchmark library. As a first-time customer, get your benchmark casting at a significantly reduced rate — covering only material and basic production costs. Evaluate our quality, accuracy, and surface finish before committing to a full project.
📦 Get a Benchmark Casting at a Discounted Rate
Submit your CAD model. Tell us the alloy and quantity. We print the mold, pour the metal, finish the part, and ship it to you — at a fraction of the standard cost. For new customers only. Evaluate our quality with minimal risk.
Request Your Benchmark Quote
Results
Rapid Prototype Casting Case Studies
Real prototype castings delivered to customers in days, not months. Every case below was produced in our own foundries on our own 3D printers.
Energy
Transformer Oil Conservator Wall
3DP sand mold printing + low-pressure casting: no traditional tooling, fast response for flexible production. High-strength ZL104A aluminum alloy ensures mechanical performance and corrosion resistance.
Automotive
Water-Cooled Motor Housing
Sand mold gas evolution below 14 ml/g and mold strength above 2.0 MPa meet the requirements of complex internal cooling-channel casting with 0.3 MPa pressure resistance. FR01 binder with high-silica sand achieves these mold specifications.
Support
Rapid Prototype Casting FAQ
Typically 5-15 business days from approved CAD. No tooling means we go straight from design to 3D printed sand molds or wax patterns to casting. Design iterations take days, not weeks. Rush service available for time-critical projects.
For complex geometries with internal cavities, undercuts, or thin walls, yes. Our 3D printed molds handle complexity that would require expensive multi-axis CNC setups. For simple prismatic parts, CNC may be more cost-effective. Talk to our engineers for a free comparison.
As thin as 2 mm for aluminum alloys via SLS wax patterns + precision casting. Sand mold casting typically 3-4 mm minimum wall. Our engineers advise on castability and suggest design modifications during DFM review to optimize for both performance and manufacturability.
Yes. This is the core advantage of rapid prototype casting. Revise your CAD file, we print new molds, and pour again. No tooling amortization. No minimum order. Each design iteration costs only materials and machine time. Many customers iterate 3-5 times before finalizing.
Yes. Send us your file or choose from our benchmark library. As a first-time customer, you can get a benchmark casting at a significantly reduced rate — covering only material and basic production costs. We print and ship a sample casting so you can evaluate quality, accuracy, and surface finish before committing to a full production order.