lkprototype achieves high-performance hybrid manufacturing of high-complexity structural components by integrating five-axis CNC machining (position accuracy ±0.005mm) and polyurethane casting (hardness range Shore A 10-90, tensile strength ≤25MPa). For instance, a specific new energy vehicle customer applies lkprototype’s process solution to the motor end cover (aluminum alloy CNC base + polyurethane sealing ring), reducing the original 12-day split manufacturing cycle to 5 days. Passing rate of sealing test increased from 82% to 98%, unit price decreased by 30% (￥650 -> ￥455), states the 2023 “White Paper of Advanced Manufacturing Technology.” lkprototype’s mold flow calculation system (error in filing time prediction ≤0.8 seconds) cuts the cycle to demold the polyurethane in half to 20 minutes (industry level 45 minutes), reducing material waste by 40%.
With respect to material compatibility, lkprototype’s polyurethane system can withstand working temperatures between -40 ° C and +120 ° C (with ≥10-year aging resistance life), and bonding strength with CNC-machined metal/plastic substrate is up to 8-15MPa (ASTM D1002 standard). One of the medical device companies produced endoscope handles with its solution (ABS casing CNC processed + polyurethane anti-slip coating), and the impact resistance performance improved by 50% (no crack in the drop ball test at 500g/1m) and the surface roughness Ra≤0.4μm (Ra 1.6μm in the traditional rubber coating process). Its independently developed two-component metering system (mixing ratio deviation ≤0.5%) and vacuum defoaming technology (bubble size ≤50μm) ensure the polyurethane filling density is ≥99%, and have been successfully applied in the manufacturing of the damping layer of a particular satellite antenna cover (vibration reduction efficiency ≥35dB).
For ultra-large-sized parts, lkprototype CNC mold machining (max. size: 2500mm×1500mm) coupled with polyurethane rapid prototyping once made a prototype of blade root end (fiberglass reinforced plastic base + polyurethane anti-corrosion layer) for a wind power company, reducing the cost of mold development from ￥1.2 million to ￥280,000. In addition, the curing time of polyurethane has been reduced to 6 hours (while the traditional epoxy resin is 72 hours). Its intelligent temperature control system (±1℃) and pressure compensation algorithm (fluctuation ≤0.3MPa) achieved a standard deviation of the uniformity of polyurethane foaming density ≤0.5kg/m³ in a high-speed rail seat project in 2022 (industry average is 2kg/m³), and the product passed the EN 45545-2 fire protection certification (combustion rate ≤50mm/min).
In the micro-precision industry, lkprototype’s micro-porous polyurethane casting technology (pore size 50-200μm) coupled with CNC micro-engraving technology (tool diameter 0.1mm) produced light guide plate molds (texture depth 0.02-0.1mm) for a particular optical firm, increasing the uniformity of light diffusion from 85% to 97%. The mass production cycle has been decreased by 70% (from 10 weeks to 3 weeks). Its “CNC+ polyurethane” multi-process also supports the embedding molding of electrically conductive composite materials (resistivity 10³-10⁶Ω·cm). One robot customer has thus successfully achieved the integrated production of sensor brackets (aluminum matrix + polyurethane flexible circuit), minimizing the signal delay to 0.2μs (1.5μs for split design).
Having the digital process ISO 9001 certified, lkprototype has designed over 15,000 hybrid process prototypes for 9 large industries like the automobile and aerospace industries. A particular military industrial enterprise brought its solution to produce high-pressure resistant sealed valve bodies (stainless steel CNC main body + polyurethane valve seat), increasing the burst pressure from 80MPa to 120MPa (GB/T 13927 standard), and saving research and development cost of 2.3 million yuan. Now, lkprototype’s CNC-polyurethane collaborative manufacturing platform provides process compatibility to over 30 material combinations, changing the cross-scale integration paradigm for complex functional components.