3. What is the Best Method to Make Your Metal Prototypes?
The scary part is that the wrong choice would not enable you to manifest the strengths of your products fully. It will also result in extra costs.
Luckily, we have got you covered. In this section, we will detail every method of metal prototyping so you can learn more about them.
Metal Machining Prototypes
Exactly the process that comes to mind first when prototyping is needed. Metal CNC machining is simply the subtractive process that reiterates future operations for large-scale manufacture but in smaller quantities.
Metal machining prototypes are also referred to as rapid prototyping. You may order third-party services, and a team of professionals will assist you in choosing the most appropriate material and manufacturing techniques.
They will G-code your CAD models, select appropriate CNC machine and tooling, and run production of test samples using subtractive machining, using mills, routers, drills, lathes, etc.
As a result, you have components manufactured precisely by your design and specifications. You also have files that can be integrated into your machinery, and the large-scale manufacture can be run easily.
As a bonus, their-party service providers may test your prototypes by the requirements of your Quality Assurance department. And any legal concerns will be covered.
Strengths
- Perfectly compatible with large-scale manufacturing processes.
- Comparatively affordable prototyping.
- Suitable for any design.
- Suitable for any material.
Weaknesses
- Typically is associated with material wastage.
- Requires skilled labor.

Metal 3D Printing Prototypes
Being considered a replacement to 3D plastic printing prototyping, metal additive machining can be a suitable process for sample production.
There are two metal additive manufacturing (AM) technologies: selective laser melting (SLM) and direct metal laser sintering (DMLS).
The simple difference is that SLM employs fully melted to the state of liquid metals. At the same time, the DMLS technique requires metal powders that are precisely deposited to create a part.
In contrast to metal machining, AM prototyping does not imply cutting off metal chips of workpieces but adds layers of material until a design is obtained.
Unfortunately, 3D metal printed prototypes do not have a great finish and suit for examining the design and aesthetics of components only.
Strengths
- Comparatively affordable prototyping.
- Does not waste material.
- Does not require that skilled labor.
Weaknesses
- Is not helpful for further running of large-scale manufacturing as it does not produce G-coded files for CNC machines.
- Parts obtained do not have the same mechanical and physical properties as the future components intended to be produced.
- The range of materials is strictly limited.

Sheet Metal Prototypes
Sheet metals are simply flat pieces of metals fabricated for the ease of further machining. They are great for some functional industrial parts that are produced in square workpieces with simple designs.
Sheet metals can be formed using the following processes:
- laser cutting
- Bending
- Punching
- Spinning
- Welding
The following techniques can be used to machine sheet metals:
- Perforating
- Slotting
- Shearing
- Piercing
- Notching
- Curling
- And others.
As a result, you obtain a part with a simple asymmetrical design and great strength. Great accuracy also can be achieved in this process.
The scary part is that you may need up to 3 machines to create a complete sheet component. At the same time, a single, for instance, 5-axes CNC machine, can perform something similar.
Strengths
- Produced components have precise dimensions and are durable.
- Suitable for the production of large quantities of prototypes.
- Is somewhat helpful for further running of large-scale manufacturing as it produces G-coded files that, in some cases, may be useful for you.
Weaknesses
- Requires skilled labor.
- Parts obtained do not always have the same mechanical and physical properties as the future components intended to be produced.
- A range of materials is somewhat limited as not any metal can be machined into sheet pieces.
- The range of designs is limited.
- Is the time consuming process.

Metal Casting Prototypes
In case you intend to produce components using metal casting, such prototyping must be your choice.
Metal casting implies melting metal to the liquid state and pouring it into a mold to form a component. In such a manner, most durable and high-quality parts can be obtained.
This process is typically a large-scale manufacturing technique, as designing and producing mold is a complicated and expensive process. It is usually done by already described 3D printing techniques, for instance.
In case you just need a small batch of prototypes, it is unlikely that metal casting is a cost-effective choice. But, if the metal casting is already the intended process for large-scale manufacture, you can receive perfect samples of both manufacturing techniques required and precise samples.
It is also great from the perspective of quality assurance. It is so because samples prepared with the same production technique as employed by a manufacturer, can serve as the basis for validation of the process.
Strengths
- Produced components have precise dimensions and are extremely durable.
- Mold can be used further in large-scale production.
- If a manufacturer employs metal casting on a regular basis, such prototyping facilitates the process of running a new production cycle.
- Suitable for the production of large quantities of prototypes.
Weaknesses
- Requires extremely skilled labor.
- Is an expensive and time-consuming process.
- The tooling required is rare and expensive.
- Is unlikely to be cost-effective if a manufacturer does not employ metal casting regularly.
Metal Extrusion Prototypes
This process is somewhat similar to metal casting. Metal extrusion is the forcing of a heated material through a die with the desired cross-section. The die shapes the comparatively soft metal in a required design, forming an elongated component.
As a result, a component with uniform cross-sections over the entire length is created. It further can be cut into equal parts, each of which is considered a distinct component.
The common types of metal extrusion are the following:
- Direct extrusion
- Indirect extrusion
- Hydrostatic extrusion
- Vertical extrusion
- Hot extrusion
- Cold extrusion
- Impact extrusion
As well as metal casting, metal extrusion can be regarded as the best choice of prototyping technique if this method is the one commonly employed on manufacture.
Strengths
- Produced components have precise dimensions and are extremely durable.
- Does not require skilled labor.
- Dies can be used further in large-scale production.
- If a manufacturer employs metal casting on a regular basis, such prototyping facilitates the process of running a new production cycle.
- Suitable for the production of large quantities of prototypes.
- It is affordable prototyping.
Weaknesses
- Requires extremely skilled labor.
- It is unlikely to be cost-effective if a manufacturer does not employ metal casting regularly.
- The range of suitable materials is limited.
