Rapid prototyping - for high precision, EMI save housings Usually investment casting is used to produce complex shaped housings. Drawbacks of investment castings are high initial costs, high costs for technical changes and limited accuracy. Finish machining is mandatory for most parts. The convenient solution is Boehm´s rapid prototyping process, which is ideally suited for precise, EMI-shielded and if necessary gas tight aluminum housings in small quantities. The process: 1. We receive CAD-data, ideally as solid model, also possible are surface, -or wire models and as well drawing or sketch 2. We cut the solid model in machineable parts. Of course the function of the component is considered for this process, i.e. flanges remain in one part. 3.We machine the parts using modern CNC-maschines 4. We electroplate the parts using the Boehm Alstan-treatment (subsequent bronze-copper-tin layers) 5. We mount the parts. The component may be checked by the design engineer in this state. If necessary changes can be applied for reasonable low cost 6. We soft solder the parts 7. We measure the component 8. We paint 9. We deliver, if required with protocol With Boehm´s rapid prototyping process a precise, EMI-shielded, and tough component is achieved. It´s properties are close to (finish machined) investment cast parts. Until now Boehm´s rapid prototyping process was used for different prototypes and some small series of housings. The components are in use for aerospace and military applications. We do see additional potential in high frequency (EMI-shielding) and high power applications (cooling, internal cooling channels). Conclusion Böhm’s rapid prototyping process: Dependent on the complexity the complete process takes between 15 to 30 working days. The design effort of our customer may be significantly reduced, if we participate in an early stage of design work. We can make an offer if we get sketches and information on the function of the housing. Precision is as good as with common milled parts. With our CAD/CAM-Systems Solid Works 2014 + CAMWorks we can read nearly all data from simple drawings to solids in different formats. (DWG, DXF, Parasolid, IGES, STEP, ACIS, VDAFS, VRML, STL, Catia Graphics, Pro/E, Unigraphics, Inventor, Solid Edge, Cad Key) Our system accepts: DWG, DXF, Parasolid, IGES, STEP, ACIS, VDAFS, VRML, STL, Catia Graphics, Pro/E, Unigraphics, Inventor, Solid Edge, Cad Key Examples for housings produced according to the Böhm process Material: Aluminum Size:400x380x380mm (16”x15”x15”) Weight: 4,5kg (10lb Surface: painted outside, tinned inside Tightness checked with 0,2bar (2,8psi) pressure in water Material: Aluminum size: 200x300x260mm 8”x12”x10” weight: 3,10kg (6,5lb) Surface: painted outside, tinned inside Tightness checked with 0,2bar (2,8psi) pressure in water