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Acrylic machining
Acrylic is one of the most commonly used plastics for machined parts in a variety of applications. Our acrylic machining includes CNC cutting, bending, mold thermoforming and surface finishing.
KUSLA is a leading supplier of acrylic machining to make customed Acrylic Products in China with integrated machining solutions including CN
Automotive prototype
Rapid prototypes in the Automotive industry are key parts of the car development process. due to the long process of the automotive development cycle is a long process, the right prototypes could help the design team validate the design in the right direction at each critical milestone. Below we will introduce our related services.
Kusla in China specializes in automotive prototyping services to custom components level Automotive prototypes include exterior and interior
Medical Device Prototype
Medical device prototype is created as early physical models of medical devices that aim to show how the product looks and operates. It can allow designers and engineers to identify opportunities and risks in the early stages of the medical device design development phase.
Kusla offers Medical Device prototypes with multiple prototyping techniques including CNC machining, 3D Printing, injection molding, and Ure
Diamond Turning: A Complete Guide
Diamond turning technology is an optical parts processing technology. Do you know how diamond turning works? Today, in this Article, we will share a complete guide with you about this technology.
Diamond turning technology is an optical parts processing technology promoted and applied by American scientific research institutions since
Urethane Casting vs 3D Printing
Urethane casting and 3D printing are known for cheap cost for small volume parts and prototype making in Various industries such as medical devices, Automotive, and Consumer products. However, Today, in this article, KUSLA will explain the full comparison to help you decide how to choose between urethane casting and 3D printing for your project .
Urethane casting and 3D printing are known for cheap cost for small volume parts and prototype making in Various industries such as medical
Aluminum Machining
KUSLA provides various customed aluminum parts by high precision aluminum machining services in China including CNC aluminum machining, Aluminum die-casting, and Aluminum extrusion.
KUSLA provides various customed aluminum parts by high precision aluminum machining services in China including CNC aluminum machining, Alu
Automotive Lighting Prototype
As the top automotive lighting prototype supplier in China, KUSLA provides high-quality prototypes including lighting optic prototypes and lit mockups which are very close to molding parts in mass production.
As the top automotive lighting prototype supplier in China, KUSLA provides high-quality prototypes including lighting optic prototypes and l
Machining Acrylic: Exploring all Processes
Acrylic is a very common plastic material that is lightweight, shatter-resistant and highly transparent, and can be used for signs, boxes, jewelry, greenhouses, lenses and many other industries. In this article, we will look at how to process acrylic.
Acrylic is a very common plastic material you can find in many industries such as signage, boxes, jewelry, greenhouses, lenses, and many mor
CNC Aluminum: How does it work?
CNC Aluminum is one of the most widely used methods for prototyping or mass production.KUSLA, as a leading aluminum machining supplier, will share with you a complete guide about CNC Aluminum including best settings and practices.
Aluminum is widely used in various industries in the world, its perfect property makes it the most popular material in the market. CNC Alumi
Low Volume Injection Molding: A Complete Guide
Injection molding is a common process for plastic part manufacturing. KUSLA, as a low-volume injection molding supplier, will share with you a complete guide to this process to help you understand what is it and how it works.
Injection molding is a common process for plastic part manufacturing but with heavy investments in Steel molds and injection machines. So, w
Complete Guide for GD&T Symbols
In order to have smooth communication between departments during the product development process, everyone needs a unique and authoritative standard. This is how GD&T became a unified standard. In this article, we'll cover everything about GD&T.
In the process of product development and manufacturing, Engineers from different departments are involved including design engineers, proce
CNC Acrylic: A Complete Guide
CNC Acrylic machining is a common method in all the processes of machining acrylic, but do you know how CNC acrylic works? today, In this article, we’ll provide a guide to understand everything about CNC acrylic including machines, best settings, best bits, and tips. This will help you create an acrylic product, especially for the beginner of CNC machining operation.
CNC Acrylic machining is a common method in all the processes of machining acrylic, but do you know how CNC acrylic works? today, In this ar
Urethane Casting (Vacuum Casting) Process: A Complete Guide
What Is Urethane?
Urethane, also known as polyurethane, is a synthetic polymer that belongs to the family of thermosetting plastics. it is a kind of resin which have similar properties to engineering plastic such as acrylic, polycarbonate, ABS, etc.
What is Urethane Casting or Vacuum Casting?
Urethane casting, also called Vacuum casting, is a process that involves using the master prototype to create a silicone mold in a vacuum state, then Casting Polyurethane and other materials through the silicone mold to clone the same replica as the master prototype. These replicas can test and verify the performance and status of products under different materials and different surface treatments.
Video of the Urethane Casting process as below:Urethane Casting
Urethane Casting Materials
Urethane Casting Materials are usually classified by the harness of the resins. they typically range in hardness from 40 shore A (soft resin) to 85 shore D (rigid resin).
Rigid Urethane (Shore D Resins)
Shore D urethane resins are a group of rigid urethanes that provide toughness and durability like engineering plastics. Different hardness shore D urethanes can be comparable to different engineering plastics such as Acrylic, Polycarbonate, ABS, HDPE, and Nylons.
Urethane Elastomers (Shore A Resins)
Shore A Urethane Elastomers are soft materials that provide great flexibility and good tear strength. They have similar physical properties to rubber and can be used for applications where soft rubber materials are needed.
Silicone
Silicones are softer than shore A materials and can be used to create some kinds of parts such as sealing, they are also commonly used to create the molds by which end-use parts are cast.
Physical Properties of Common Urethane Casting Materials
Here we summarize a table to show the Physical properties of Common Urethane Casting Materials in our Urethane Casting services.
Vacuum Urethane Casting process steps
Step 1: Create a Master prototype by CNC machining or 3D Printing, CNC machining is preferred if high precision replica is needed for Urethane Casting prototypes.
Step 2: Make a silicone mold in a vacuum environment, pour liquid silicone over the master prototype, and let it cure. The mold is usually split into two halves for easy removal of the cast part.
Step 3: Cast Urethane resin, The mixed urethane material is poured into the mold cavity and cured to form the parts.
Step 4: Open The Mold, Once the Urethane material has cured, the mold is opened and the cast urethane part is carefully removed.
Step 5: Post Finishing, the cast part usually needs post finishings such as trimming, sanding, painting, or other surface treatments.
Urethane Casting Machines
A vacuum urethane casting machine is used for mixing, casting, and curing. Operators control parameters like pressure and temperature. The machines are of different sizes and can work with various materials. Some common machines are as below:
Renishaw 5/01 PLC: Handles molds up to 530 x 450 x 420 mm
SLM VCM 04: For molds up to 750 x 750 x 900 mm.
MCP 5/01: Suitable for parts up to 400 x 400 x 400 mm. Offers larger models.
Scott AM 1000: Handles molds up to 500 x 450 x 425 mm.
Multistation CSV 340: Capable of molds up to 340 x 340 x 435 mm.
Advantages of Urethane Casting
High precision: Urethane casting can duplicate all details of the master prototype made by CNC machining including the accurate dimensions and surface quality.
Short lead time: urethane casting prototypes can be made within a few days for low-volume production which can significantly save the time of the product development.
Cost saving: Urethane casting uses silicone mold which is a cheap tooling and the Urethane resin material is also cheap compared with what is used in injection molding.
Design flexibility: Silicone mold does not need much draft angle and ok for the undercuts which can give the design more room to be flexible design.
Multiple Material Offerings: Multiple Urethane resin materials can be chosen for different applications, and they can be customed for special colors and other properties.
Excellent Surface Finish: like injection molding, cast urethane parts offer an excellent surface finish because the parts can be colored, textured, and painted.
Applications of Urethane Casting
Rapid Prototyping
Cast urethane is often used to make a small number of prototypes for testing or other evaluations by engineers. This is mainly because of the low cost and fast lead time compared with CNC machining when using a certain quantity.
Low Volume Production
Because urethane casting is a consistent, flexible, and precise manufacturing process, when a project’s volume is low, using hard tooling will be not a cost-effective solution, Urethane casting will be the perfect solution to balance quality and cost in terms of low-volume production.
Urethane Casting VS. Alternatives
Urethane Casting Vs. Injection Molding
Urethane casting is used for low to medium-volume production in a short time. It’s a cost-effective option. In contrast, Injection molding is used for high-volume and consistent production but needs a longer setup time.
Read more about Urethane casting vs injection molding.
Urethane Casting Vs. 3D Printing
Urethane casting can make high-quality parts in small quantities with diverse resins. 3D printing is for rapid prototyping which has lower quality parts with lower quality requirements.
Urethane Casting Vs. CNC Machining
Urethane casting and CNC machining are different production techniques, CNC is better for only 1 or 2 prototypes needed with high precision. Urethane casting can duplicate the CNC master prototype to create more parts which means cost and time saving.
Read more about CNC Machining vs Urethane Casting
Design Guidelines for Urethane Casting
Wall Thicknesses
even the minimum thickness could be 1mm, but if possible, Make the wall thickness between 1.5 mm – 4 mm. Over thick or less thickness causes defects on the final parts like injection molding.
Ribs
add ribs to improve part strength, and make the rib thinner at 60% of wall thickness to avoid shrinkage. And Avoid 90-degree walls which are easy to break.
Radius
Make a radius more than 3mm to improve part strength and be good for silicone tooling lifespan.
Draft Angle
Even the Urethane Casting process is possible to make it without draft angles, but if possible, make 3 degree draft angles which will be better for the lifespan of the silicone mold.
Conclusion
Urethane casting is not an easy job and is very practical for rapid prototyping and low-volume manufacturing. In KUSLA, we have decades experiences of Urethane casting service and make lots of parts for our customers. our advantage is we can make it fast at low cost. contact us today, and you will find it.
This post is reprinted from https://www.kuslaprototype.com/urethane-casting-vacuum-casting
Common Aluminum Alloys for Machining
Aluminum alloys are widely used metals in various industries. There are many different types of aluminum alloys with different names in the market. how do you know which one is suitable for your project? where are the differences between each type? how they are named? in this blog, we will give you answers to these questions.
What Is Aluminum Alloy?
Aluminum alloys are mainly composed of pure aluminum, combined with other elements such as copper, silicon, magnesium, and zinc to improve its properties. aluminum alloys are lightweight and have excellent corrosion resistance and good electrical and thermal conductivity.
How Aluminum Alloy is Named
When we see the name of aluminum alloys. You may wonder what number and letters means, such as 6061, 6061-T6, and 7075-T651. As below, we take an example of 6061-T6 to explain to you.
The first number “6″ represents the aluminum alloy group, and its detailed meaning as below:
the second number “0” Indicates the control of alloying elements or impurities’ maximum content as below:
the number "61" represents a kind of alloy within the same group .The rest letters meanings are as below:
For example, “6061-T6” indicates an alloy from the aluminum-magnesium-silicon series that has undergone solution heat treatment and artificial aging to achieve a stable temper.
Types Of Aluminum alloy
Wrought Aluminum Alloy
Wrought aluminum alloys have a big portion of all kinds of aluminum alloys. they are divided into heat-treatable and non-heat-treatable alloys. they contain Copper, magnesium, and zinc which provide their initial strength. Corresponding to series 2xxx, 6xxx, and 7xxx, Heat-treatable wrought aluminum alloys can be strengthened further through heat treatment. Non-heat treatable Aluminum Alloy corresponds to the 1xx, 3xx, and 5xx series of wrought alloys, it can be strengthened further through strain hardening or cold working.
Cast Aluminum Alloys
Aluminum alloys for die casting have several types like aluminum-silicon, aluminum-copper, aluminum-magnesium, aluminum-zinc, and more. The common grades for die-casting aluminum alloys are defined by the standards of Japan’s JIS and ANSI. The table below shows common die-casting grade series under various standards.
Advantages of Aluminum Alloys
Easy to machine
Aluminum alloys are relatively soft compared with other metals such as Steel. this characteristic makes it easy to be cut by the CNC bits and molded, and then result in aluminum parts with high precision and consistency.
Lightweight
Aluminum alloy’s density is 2.7 g/cm³ which is one-third the density of steel. This makes Aluminum alloy lightweight and widely used a lot in applications that need lower weight such as the Automotive industry.
Corrosion Resistance
Aluminum can form a thin protective oxide layer on its surface naturally, This protective aluminium oxide layer helps protect the surface of the aluminum part from corrosion.
Electrical and Thermal Conductivity
Aluminum alloy is an excellent conductor of heat and electricity. its conductivity is much better than steel and other metals but not copper which makes it widely used in lots of Electrical components. It is also used as a heatsink in a variety of applications to conduct heat.
Strength-To-Weight Ratio
Even though aluminum alloy is lightweight, aluminum alloys still provide excellent strength and structural integrity. this makes them widely used in various applications where strength and weight need to be balanced.
Recyclability
aluminum is 100% recyclable and it can retain all of its original properties after recycling, this makes aluminum a much more cost-effective source material for production.
Common Aluminum Alloys for Machining
Aluminum alloys can be used for different machining processes such as CNC machining, sheet metal fabrication, extrusion, and die casting. Based on the Characteristics of each machining process, different types of aluminum alloys are used. Here we list the common aluminum alloys for different machining processes.
For CNC machining
2024-T4: primarily used in the aerospace industry
5052: often used in the marine industry
6061-T6: most widely used in various industries.
6063: moderate strength and high ductility
6082: used in the construction industry
7075-T6: it is used in the aerospace and military industry
Read more in our blog about CNC Aluminum, you will get more details from it.
For Aluminum Extrusion
6005: contains silicon content which enhances extrudability.
6063: widely used in custom structural pipes, tubing, and heat sinks.
6463: used for various custom profiles.
For Aluminum die-casting
A360: Its applications include the manufacture of automobile oil pans, automobile controller shells, motor shells, 5G communication boxes, LED lamp housings, and more.
A380: It is used for products like electrical equipment chassis, engine mounts, gearboxes, furniture, generators, and hand tools.
A383: the most common die-casting aluminum alloy used in the market. it is equivalent to ADC12 according to JIS standards.
For Sheet metal fabrication
6061: most widely used in various industries.
5052: often used in the marine industry
Physical Properties of Common Aluminum Alloys
Here we summarize a table below to show all the physical properties of aluminum alloys, so then you can understand the performance of each aluminum alloy.
How to Choose an Aluminum Grade?
Before you choose aluminum, you will need to consider your machined parts requirement and the machining process you will use. some of the general considerations are as below:
Strength Requirements from the above introduction of each aluminum alloy, you will find their strength properties. Aluminum 7075 has the best strength among those.
Corrosion Resistance Consider the environment in which your aluminum components will be exposed. Some aluminum alloys offer exceptional corrosion resistance like 5052 or 6061, known for their corrosion resistance.
Weldability If your project requires welding, ensure that the chosen aluminum grade is weldable. aluminum 6061 is more weldable than 7075.
Machinability If you will use aluminum alloy for CNC machining, it is better to choose one easy to be machined. Aluminum 6061 has good Machinability for machining.
What is the best aluminum alloy for CNC machining?
Generally speaking, According to the market data, 6061-T6 is the most popular aluminum alloy for CNC machining. It’s versatile and easy to machine, 6061-T6 is a general-purpose material applicable for many applications.
However, Using a proper Aluminum alloy for your products is the key to quality. you may need to choose a professional supplier who is capable of managing different types of aluminum alloys. KUSLA has rich experiences in aluminum machining services that can help you with your projects. contact us today to get an instant quotation.
You may also want to know about the Methods for creating metal prototypes, please click the link to view our blog.
This post is printed from https://www.kuslaprototype.com/aluminum-alloys-for-machining
ABS Prototype: Materials, Processes, Advantages, Applications
As we all know, the plastic prototype is critical during the product development process, they are used for validation tests before the design release. ABS plastic, as one of the most widely used materials in rapid plastic prototypes, is widely used in various industries. in this article, we will explore how to make the ABS prototype and why it is so popular in the current world.
What is an ABS prototype?
An ABS prototype is a physical model created before mass production with ABS plastic material. ABS means Acrylonitrile butadiene styrene and is widely used for creating plastic prototypes due to its ease of machining such as CNC machining, 3D printing, and injection molding.
ABS Material Properties
ABS is a terpolymer composed of acrylonitrile(15-35%), butadiene(5-30%), and styrene(40-60%). these elements give ABS several major properties as below:
Chemical stability: ABS plastic is resistant to most chemicals such as acids, alkalis, minerals, and vegetable oils.
High Dimension Stability: ABS parts can maintain dimensions and their properties over a long time.
High Strength: ABS material has both high mechanical strength and impact strength, making it withstand high impact without loss of its properties.
High rigidity: ABS material has high hardness, which makes it rigid and resistant to scratches and abrasions
Excellent surface: ABS parts have an excellent surface which makes them widely used for aesthetic parts.
ABS material grades for plastic prototyping
There are different grades of ABS materials used in plastic prototyping and part manufacturing. Here are some common grades.
ABS General Purpose grade
General Purpose ABS has good machinability and can cover most of the applications of the ABS prototypes. it can be processed by extrusion to create ABS sheets which could be used by CNC prototyping and thermoforming to custom ABS prototypes. it also can be used by prototype injection molding process to create injected ABS prototypes.
ABS Flame Retardant Grade
Flame Retardant ABS is used for applications where flame resistance and heat resistance are needed such as electronic device housings. it is made by adding flame retardants to the base ABS material. it can be molded or extruded for different plastic prototyping processes.
ABS High Impact grade
High-impact grade ABS has better strength and toughness than general-purpose ABS. this grade ABS is commonly used where high impact resistance is required such as in toys and automotive components.
ABS UV-Resistant grade
UV-resistant grade ABS is widely used in outdoor applications due to UV radiation outdoors may cause degradation or color fading in general grade ABS. it is made by adding UV-resistant additives to the base ABS materials.
Advantages of ABS material in Rapid plastic prototyping
Easy to machine
ABS materials are easy to machine like milling, bonding, and cutting without breaking and injection with fewer defects than other materials. It applies to different plastic prototyping processes such as CNC machining, 3D printing, Urethane casting, and injection molding.
Easy for post-surface finishing
ABS is easy for the post-surface finishing of plastic prototyping such as painting, polishing, and sanding which can give the ABS prototype a good-looking appearance.
Cost-effective
ABS is a cheap material compared with other plastic materials such as polycarbonate, the cost is important for a prototype project. this is why engineers choose ABS when the project has a low budget.
Outstanding material properties
ABS material has good strength, good impact resistance, heat resistance, low-temperature resistance, and chemical resistance, making it the most widely used plastic in prototypes and parts making.
ABS plastic prototyping processes
CNC machining ABS
CNC machining can make high-accuracy ABS prototypes by CNC milling, CNC turning, and drilling on ABS sheets. it uses a rotating cutter to remove the material from the ABS blocks to form the shape according to the 3D data.
3D printing ABS
FDM(Fused Deposition Modeling) 3D printing is the most popular process for ABS plastics. it is an additive manufacturing process that creates ABS prototypes layer by layer till it creates a full physical part on a 3D printer. this process creates ABS prototypes very fast with a minimum lead time of hours.
Vacuum casting ABS
Vacuum casting involves using a silicone mold to cast ABS prototypes with a low cost for low-volume manufacturing, usually less than 100 pieces.
Prototype injection molding ABS
Prototype injection molding makes ABS prototypes with rapid injection tooling for the volume from 100 to 10,000 pieces. ABS prototypes created by this process have excellent surface qualities and high accuracy.
Applications of ABS prototypes
Automotive parts
The strength and toughness of ABS materials make them ideal for hand-panel prototypes of automotive parts, such as dashboards, doorknobs, etc., which can help engineers assess the feasibility of a design before actual production.
Electronic product housing
The good dimensional stability and surface treatment ability of ABS material make it suitable for the production of housings of mobile phones, tablets, laptops, and other electronic products, and these prototypes help to verify the appearance of the product design and assembly structure.
Medical devices
ABS prototypes play an important role in the design verification of medical devices, such as surgical tools, diagnostic equipment, ventilators, and more. these ABS prototypes are to ensure product safety and ergonomic design.
Toys
The toughness of ABS material makes it an ideal choice for making toy prototypes, such as remote-controlled cars, robot models, etc., which can help designers evaluate the appearance and structure before mass production.
Aerospace
The lightweight and strength of ABS materials make them suitable for making prototypes of small drones, aircraft, etc., which are used for evaluating aerodynamic design and structural strength.
Alternatives of ABS material for plastic prototyping
PC(Polycarbonate)
Polycarbonate is known for its high strength, impact resistance, and thermal resistance. it can replace ABS used in those applications where high strength and thermal resistance are required.
Modified PP(polypropylene)
Modified PP is widely used to replace ABS material to costs down. For example, PP(G204D) is suitable for applications with high impact requirements, while PP(HG3230) is used in applications with high rigidity requirements, and its shrinkage is close to or smaller than ABS.
PA6 (polyamide 6) :
PA6 can replace ABS in terms of rigidity and toughness and has the advantages of fatigue resistance and low density and weight.
ASA Resin:
ASA resin is equivalent to ABS in mechanical properties, and better than ABS in weather resistance, solvent resistance, and coloring properties, it is also an important engineering plastic.
Conclusion
After reading this article, you will understand the ABS material’s properties, grades, advantages, and applications. And also the processes of creating ABS prototypes. if you want to know more about how to create a plastic prototype, check out our blogs. KUSLA is a rapid prototyping factory that is capable of making high-quality ABS prototypes with all these processes and helps you find a low-cost way to meet your project requirements.
This post is reprinted from https://www.kuslaprototype.com/abs-prototype
6061 aluminum vs 7075 aluminum
What Is 6061 Aluminum Grade?
Aluminum grade 6061 is one of the most commonly used aluminum alloys. it is the most famous member of the 6000 series of aluminum alloys. Due to the perfect balance of hardness and machinability, 6061 aluminum alloy is referred to as structural aluminum. it is Composed primarily of aluminum(97.9%) and magnesium, silicon, copper, chromium, and a tiny amount of other elements.
What Is 7075 Aluminum Grade?
Aluminum 7075 is a high-strength heat-treatable aluminum alloy used for highly stressed structural parts. it is a member of the 7000 series aluminum alloys. As a primarily zinc-based aluminum alloy, It contains 5.6% zinc, 2.1% magnesium, and 1.2% copper.
Differences Between Aluminum 6061 and 7075
6061 Vs. 7075 Aluminum: Chemical Composition Comparison
Below is a table to show the Chemical Composition of both materials and you will find how each Chemical affects the performance of the materials.
6061 vs. 7075 Aluminum: mechanical properties comparison
A comparison table is below for the mechanical properties of both materials.
Tensile Strength
This property measures a material’s resistance to a longitudinal pulling force. Aluminum 7075 is very good in this aspect, making it ideal for applications where high strength is critical, such as aerospace components.
Yield Strength
Yield strength indicates the point at which a material begins to deform plastically. Aluminum 7075 has a higher yield strength compared to 6061, which means its superior ability to withstand deformation.
Hardness
Hardness means a material’s resistance to surface indentation or abrasion. Aluminum 7075’s hardness is higher than that of aluminum 6061, making it more resistant to wear and damage.
Elongation
Elongation measures how far a material can stretch before breaking. Aluminum 6061 is more ductile in this aspect, meaning it can deform significantly before reaching its breaking point compared to 7075.
Young’s Modulus(Modulus of Elasticity)
This property defines a material’s stiffness and its ability to return to its original shape after deformation. Both alloys have similar values, but 6061 is slightly more elastic, making it better suited for applications requiring flexibility.
Thermal Conductivity
It means how efficiently a material conducts heat. Aluminum 6061 has higher thermal conductivity, making it suitable for heat dissipation applications like heat sinks.
Electrical Resistivity
This property quantifies a material’s opposition to electrical current flow. 7075 has slightly lower electrical resistivity, making it better for electrical conductivity applications.
Elasticity
Elasticity reflects a material’s ability to deform and regain its original shape under applied stress. Aluminum 6061 has higher elasticity, allowing it to flex more without permanent deformation.
Temperature Resistance
This property indicates how well a material can withstand elevated temperatures. Aluminum 7075 is better in high-temperature environments due to its higher melting point.
Corrosion Resistance
6061 vs. 7075 Aluminum: machinability comparison
CNC Machinability
Aluminum 6061 is easy to machine, and used for producing longer, continuous chips during CNC Aluminum machining. On the other hand, Aluminum 7075 is also machinable, but it generates shorter, segmented chips. so, for CNC machinability, 6061 aluminum will be better.
Weldability
In terms of weldability, Aluminum 6061 is better. It is adaptable to various welding techniques, including TIG and MIG welding with a good result. Although Aluminum 7075 is weldable, it demands more expertise and careful control of welding parameters.
Bending
For bending operations, Aluminum 6061 is highly formable and can be bent to various angles without the risk of cracking or distortion. In contrast, Aluminum 7075 is less ductile and possible to crack during bending.
Sawing
Both alloys can be cut effectively, but Aluminum 6061 is easier to cut. Standard sawing equipment can easily cut 6061, ensuring precise and clean cuts. Aluminum 7075 requires specialized sawing equipment for optimal cutting results.
EDM (Electrical Discharge Machining)
Wire EDM is not commonly used on Aluminum 6061 due to its excellent machinability using conventional methods. For Aluminum 7075, EDM is a viable option, especially in cases demanding high-precision components.
Tool Wear
Tool wear is a key consideration during machining. Aluminum 6061 shows low tool wear. Aluminum 7075, while still machinable has high tool wear due to its high hardness.
Surface Finish
Aluminum 6061 generally delivers a smooth surface finish, making it an excellent choice when aesthetics is important. Aluminum 7075 can also achieve a satisfactory surface finish, but it may require more effort due to its high hardness.
6061 VS 7075 Aluminum: How To Choose?
With the answer to the following three questions, you will know how to choose.
Which One is Stronger: 6061 or 7075 Aluminum?
7075 aluminum alloy has a higher yield strength compared to 6061 aluminum, So it can withstand impacts better than 6061.
Which One is Easier to Machine: 6061 or 7075 Aluminum?
6061 aluminum has lower tensile strength and hardness compared to 7075 aluminum. So, 6061 aluminum is easier to machined and shaped.
Which One is More Cost-Effective?
The raw material cost and machining expenses for 7075 are higher. So Aluminum 6061 is more cost-effective.
When to choose: 6061 or 7075 Aluminum
According to the comparison above, we summarize a when list to help you decide how to choose.
Aluminum 6061 can be considered for use in the following situations:
When parts require a lot of welding process.
When there’s a high demand for corrosion resistance.
When a lower cost is a priority.
7075 aluminum is more suitable for the following situation:
When achieving a high strength-to-weight ratio is needed.
When parts need to withstand high temperatures.
When parts will be subjected to high stress.
When the budget allows for higher material costs.
Conclusion
6061 and 7075 Aluminum alloys are both wonderful in the machining process. if you can not decide well, Contact a professional aluminum machining supplier. KUSLA is a manufacturer of precision aluminum machining in China. Feel free to get in touch with us for your aluminum machining projects.
You may also interested in other comparisons:
Titanium vs Aluminum
this actical was printed from
After we introduced Common Aluminum alloys used for machining. Today, we continue to introduce Specifically two aluminum grades 6061 Aluminu
Urethane casting is a process that utilizes a two-part urethane resin to produce production-quality prototypes. it creates highly precise replicas of a master pattern. it is a cost-effective and fast turnround method for creating rapid plastic prototypes.
Urethane casting is widely used across industries like automotive, aerospace, medical, and consumer goods, particularly when intricate parts with complex geometries require low volume precise replication.
If you need this service you can contact us.