Inside Vacuum Casting

Vacuum casting is used for rapid production of small numbers of highly accurate polyurethane resin parts with characteristics and quality comparable to a final injection moulded product.

These parts can be used as prototypes or production parts. The key benefits are speed, high quality and exact replication of the desired parts.

The parts are cast from a silicone master mould which is typically made using an SLA master part.

The beauty of this process is the production of the part in a vacuum chamber, resulting in the complete elimination of bubbles in the resin material. The vacuum casting process delivers an extremely fine level of detail and a high quality, blemish-free surface, so that prototype parts can be passed off as the real thing.

At the same time, due to the high quality finish achievable, small numbers of high quality production components can be produced to a manufactured finish.

How does Prototype Projects produce vacuum casting parts?

Prototype Projects has a fully equipped Vacuum Casting suite with multiple vacuum casting machines. We also have our own in house 3D printing facilities which are used for producing the master pattern. For best quality, we use high definition SLA models.

Because we do everything in-house, including production of the SLA master, the vacuum casting itself, and painting or lacquering to achieve the desired finish, our Project Manager will see your vacuum casting project through each stage of its journey from your initial CAD file through to the final parts and assemblies.

Time to manufacture depends on your desired characteristics. Part size (due to the time required for curing), level of quality and finishing requirement are all key factors.

When it comes to Vacuum Casting, Prototype Projects has the whole process covered in-house from beginning to end.

See our vacuum casting video

Or download a Datasheet PDF

Vacuum Casting FAQ

What are the main benefits of vacuum casting?

• Highly accurate replication of patterns, profiles and textures
• Less expensive than hard prototype and production tooling
• Fast production
• Very high quality
• Very fine levels of detail
• Wide range of materials/properties including:
  • Water clear
  • Flexible polyurethane casting resin grades range
  • Range of spark texture grades, smooth matt and satin to a high gloss finish
• Can be painted and/or lacquered
• Parts can be drilled, tapped or have threaded inserts moulded in

What are vacuum cast parts used for?

• Prototypes for e.g.
  • Pre-production functional testing
  • Assembly line trials
  • Marketing presentations and trade shows
• Small runs of production parts

How long does a silicone mould last?

• A typical mould will produce 20 – 25 parts before new tooling is necessary

What properties can be achieved with vacuum casting parts?

• Flexibility and rigidity
• Heat resistance
• Transparent, tinted or coloured material
• Fire resistance
• UV stability
• Range of surface finishes
• Threaded insert options

What can vacuum casting parts used for?

• Components and small products
• Plastic lenses
• Trims
• Scientific and healthcare products

What materials are offered?

Polyurethane simulation of the following:

• ABS
• POM
• Elastomers (Range: 25 – 95 Shore A)
• Nylon including Glass Filled
• Polypropylene

Which industry sectors use vacuum casting?

• Design consultancy sector
• Consumer products
• Automotive
• Medical devices
• Scientific instrumentation
• Electronics/computing

GOT A VACUUM CASTING REQUIREMENT?

Contact Prototype Projects on 01763 249760 or click here to request a quote.