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Researchers have developed a new rapid-prototyping technique that blends traditional casting methods with CNC milling which allows faster prototyping; the best thing is that it happens in a single machine. The technique is christened as "Precise Cast Prototyping" or PCPro and was developed by researchers at the Fraunhofer Institute For Material and Beam Technology, Dresden, Germany. Half of the mold is machine using CNC machining, then silicon or polyurethane material is poured into fill half the mold, this will be the lower half to render the shape of one half of the part, while the part still in the CNC mill. When the material is cured and hardened, the upper side of the component is milled. The process is targeted at components with simple geometry such as housings whose one side can be fairly easily machined on aluminum or epoxy mold half and the other complicated half is on the opposite side where it can be milled into the soft plastic.
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