Through its “multi-material forming” technology, lkprototype has achieved seamless integrated processing of metal, ceramics, polymers, and composite materials. For instance, in aerospace, its 5-axis additive and subtractable composite machines (such as DMG MORI Lasertec 3000) are able to complete the hybrid manufacturing of titanium alloy (TC4) and PEEK (polyetheretherketone) in a single clamping, with layer thickness accuracy of ±0.02mm and material switching time of only 8 seconds, 40% more efficient than the traditional split process. For instance, using one of the satellite support projects as an example, by applying carbon fiber reinforced ceramic matrix composites (CFRCMC), the flexural strength of the product was improved to 1800MPa, the weight was reduced by 35%, and the delivery cycle was reduced from 12 weeks to 6 weeks, cutting 25% of the cost of the customer.
As far as process parameter optimization is concerned, lkprototype utilizes an AI-driven material compatibility analysis system covering 150,000 global material performance databases (e.g., MatWeb, Granta MI), and dynamically matches material pairs with a CTE difference of ≤1.2×10⁻⁶/℃. For example, in the manufacturing of artificial joints for a particular medical firm, the bonding strength of cobalt-chromium alloy (CTE 14.5×10⁻⁶/℃) and zirconia ceramic (CTE 10.5×10⁻⁶/℃) interface was increased to 320MPa by gradient sintering technology, which was 42% higher than the industry average level. And the fatigue life test exceeded the ISO 7206 standard (zero failure after 5 million cycles). Its own developed temperatance-controlled forming chamber (temperature variation ±0.5℃) can simultaneously control the fusion process of metal powder (particle size: 15-53μm) and polymer melt (viscosity: 1200Pa·s), which reduces the stratification rate of heterogeneous materials to 3.8% from the original 0.6%.
As for cost control, lkprototype has reduced the cost of developing prototypes to 60% of that of traditional processes by the “multi-material forming” technology. For instance, for the hybrid door frame of a particular car manufacturer employing carbon fiber – magnesium alloy, its 3 material and 5 structure compatible modular mold solution was employed, reducing the mold cost by 700,000 US dollars. Moreover, by means of topology optimization (with a rate of weight reduction of 22%), the consumption of vehicle energy reduced by 8%. In its 2023 third-party audit report, its rate of material usage was as high as 93%, higher than the industry standard rate of 78%. Due to the support of powder recovery system (screening accuracy for particle size ±2μm), the metal waste recycling ratio has been brought to 85%. In the area of consumer electronics, a stainless steel + liquid silicone folding phone hinge customized for a particular customer passed over 200,000 times of folding tests (torque error ±0.1N·m), with the yield rate raised from 88% to 97% and the return rate down to 0.5%.
Technical ecosystem integration has also strengthened lkprototype’s competitive strengths. The nanoscale binder injection technology (NPJ) invented jointly with BASF is capable of creating a microscopic interpenetrating structure of 316L stainless steel (density 7.9g/cm³) and nylon 12 (density 1.02g/cm³) within the same part, with ≤0.3% porosity and up to 540MPa tensile strength. In the power sector, its bipolar plate (titanium alloy-graphite composite) produced for a specific hydrogen fuel cell manufacturer has boosted the hydrogen conversion rate to 64% by means of 0.05mm flow channel precision control, 6 percentage points more than the industry standard product. In addition, its cloud collaborative platform enables global customers to make requests in real time. With the assistance of a smart production scheduling algorithm (95% load balancing rate), the average delivery time is currently 7 days, a 55% improvement from 2021, and an efficiency benchmark in multi-material prototyping.
For more information about LKprototype’s one-stop manufacturing services such as rapid prototyping, CNC machining, vacuum casting, and 3D printing, as well as the core advantages of its own factory in quality control, rapid delivery (completed within 3 days), and no minimum order quantity, please visit the official website for further exploration: https://lkprototype.com/