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Metal Prototype Machining Services - Istar Machining
Metal prototype machining is the process of creating first-article metal parts using CNC technology before full production. At Istar Machining, we turn your designs into real, working metal prototypes with tight tolerances and production-grade materials.
Our CNC machining service creates prototypes that look, feel, and work just like final production parts. This helps you test and improve your designs before spending money on mass production.
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Supports uploading of the following file formats: .STEP .STP .SLDPRT .STL .IPT .3MF .3DXML .PRT .SAT .DXF .X_T .X_B .JT .CATPART
- All uploads are secure and confidential.
20+ Years
Istar Machining's years in the industry
300,000 square feet
The size of Istar Machining's factory
300 CNC machines
Our CNC equipment count
1000 skilled workers
Istar's number of skilled machinists/operators
Key Features of Our Metal Prototype Machining
- Rapid Turnaround: Get your metal prototypes in just 3-5 days
- High Precision: Achieve tolerances as tight as ±0.001″ (0.025mm)
- Material Options: Work with aluminum, stainless steel, titanium and more
- DFM Support: Free design feedback to improve manufacturability
- ISO Certified: Quality management systems for consistent results
- Competitive Pricing: Cost-effective for single prototypes or small batches
Materials We Machine for Prototypes
Material Type | Common Grades | Key Properties | Best For |
Aluminum | 6061, 7075 | Lightweight, corrosion-resistant | Aerospace parts, consumer products |
Stainless Steel | 304, 316 | Strong, rust-resistant | Medical devices, food equipment |
Titanium | Ti-6Al-4V | Highest strength-to-weight ratio | Implants, aerospace components |
Brass | C360, C260 | Good electrical conductivity | Electrical components, decorative parts |
Copper | C101, C110 | Excellent thermal conductivity | Heat sinks, electrical connectors |
Steel | 1018, 4140 | High strength, affordable | Tooling, industrial equipment |
Need help choosing the right material? Our engineers can help select the best option for your prototype’s needs and budget.
Our Metal Prototype Machining Process
- Submit Your Design: Upload your CAD files (STEP, IGES, or other formats)
- Get a Quote: Receive pricing within hours, not days
- Design Review: Our team checks your design for machining issues
- Prototyping: We machine your part using our advanced CNC equipment
- Quality Check: Each part is inspected to confirm it meets specifications
- Delivery: Your prototype ships directly to your facility
Visit our CNC prototype machining page to learn more about our streamlined process.
Industries We Serve
Aerospace
We create precision aerospace prototypes with tight tolerances for testing in demanding environments. Our machining meets strict industry standards.
Medical
Our biocompatible prototypes for FDA-approved devices are machined from medical-grade metals with extreme precision for surgical tools and implants.
Automotive
We help accelerate R&D cycles with rapid prototypes for EV components, brackets, and housings that mirror production parts in form and function.
Consumer Electronics
Our team delivers sleek, functional prototypes with superior finishes ready for anodizing or powder coating for enclosures and heatsinks.
Robotics
We machine high-strength, lightweight prototypes for robotics applications, optimized for dynamic performance in actuators and joints.
Machining Processes We Offer
We use different machining techniques depending on your prototype needs:
CNC Milling
Perfect for creating complex shapes and features in metal blocks. Our CNC milling creates precise flat surfaces, pockets, and 3D contours.
CNC Turning
Ideal for round parts like shafts, pins, and cylindrical components. Our lathes create perfectly concentric features with tight tolerances.
5-Axis Machining
For the most complex geometries, our 5-axis machining can create parts with features on multiple sides in a single setup.
Quality and Tolerances
Quality is at the heart of our metal prototype machining service:
- Standard Tolerances: ±0.005″ (0.127mm) for most dimensions
- Precision Tolerances: ±0.001″ (0.025mm) when specified
- Surface Finish: Ra 0.8–3.2 μm depending on requirements
- Inspection: CMM verification with detailed reports available
- Material Certifications: Available upon request
Advantages of Metal Prototype Machining
Test Before You Invest
Metal prototypes let you test fit, form, and function with real materials before spending on expensive tooling or mass production.
Fast Iteration
Make changes to your design and get new prototypes quickly to speed up your development process.
Marketing and Fundraising
High-quality metal prototypes make a better impression when showing your product to investors or potential customers.
Regulatory Testing
Submit machined prototypes for regulatory testing and approval before final production.
Common Usage Scenarios
Usage Scenario | Description | Benefit |
Functional Testing | Test how your part works under real conditions | Validate performance before production |
Fit Checking | Ensure components fit together properly | Avoid assembly issues later |
Design Validation | Test the look and feel of the product | Get feedback on ergonomics and aesthetics |
Pre-Production Samples | Create small batch before full production | Final verification before scaling up |
Replacement Parts | Recreate obsolete or custom components | Extend equipment life |
What Makes Istar Machining Different
Engineering Support
Our team doesn’t just machine parts – we provide valuable design for manufacturability feedback to improve your prototype’s design.
Advanced Equipment
We use the latest 5-axis CNC machines and high-precision tools to create complex prototypes that other shops cannot handle.
Material Expertise
With years of experience machining exotic alloys and special metals, we can help select the right material for your prototype’s needs.
Competitive Pricing
Our efficient processes and dedicated prototype cells allow us to offer competitive rates without sacrificing quality.
Post-Processing Options
Enhance your metal prototype with our finishing services:
- Anodizing (Type II and III for aluminum)
- Passivation (for stainless steel)
- Bead Blasting
- Powder Coating
- Plating (nickel, chrome, gold)
- Heat Treatment
- Polishing
- Custom Marking/Engraving
How to Order Your Metal Prototype
Getting started with Istar Machining is easy:
- Contact us with your project details
- Send your CAD files for review
- Receive and approve your quote
- We machine your prototype
- Your finished parts ship directly to you
For specialized requirements, check our metal prototype machining page for detailed information.
Ready to Start Your Metal Prototype Project?
Contact Istar Machining today to discuss your metal prototype machining needs. Our team is ready to help bring your designs to life with precision and care.
Frequently Asked Question
We have no minimum order. We can make just one prototype or small batches of 1-500 parts.
Our standard lead time is 3-5 days. Rush services are available for urgent projects.
We accept STEP, IGES, X_T, Solidworks, and most other 3D CAD formats.
Yes, our engineers can help refine your design for better manufacturability.
Absolutely! Iterative design is common in prototyping. We can quickly machine revised versions.
