What is Vacuum Casting?
Vacuum Casting is used to produce small numbers of polyurethane prototype parts with mechanical properties similar to injection moulded polymers. As the name suggests, a vacuum is used to push the material into the tool.
We can produce parts to excellent levels of detail and keep tooling concessions to the absolute minimum.
Call us to discuss what CAD requirements we need to start your project.
When to use Vacuum Casting
Pre-production prototypes
Limited production volumes
Functional testing
Assembly line trials
Marketing purposes e.g. presentations and trade shows
Add value to your projects
Please contact us to request a quote for your vacuum casting project.
Our in-house Vacuum Casting facilities
We have a suite of Vacuum Casting chambers and ovens, which afford great flexibility in turning around tools quickly.
These systems feature electronic differential pressure systems and automatic silicone de-gassing. Our specialist process curing ovens ensure excellent surface quality with a minimal scrap rate.
Vacuum Casting Technical Details
- Maximum casting weight: 1400 g
- Maximum mould size: 450 x 470 x 400 mm
Vacuum Casting datasheet
Download our datasheet for more detailed information about Vacuum Casting.
What is the Vacuum Casting Process?
The Vacuum Casting process is typically used to produce small numbers (usually up to 20) of polyurethane prototype parts.
It is a slightly slower process than SLA alone because of the additional steps involved in the process, some of which are manually intensive. The time to manufacture depends on the desired characteristics of the part, with size being a key factor as this affects the curing time of the material.
Parts are made from a master pattern, which is made using an SLA 3D Print. The master pattern will be finished in the desired surface finish of the final part; This can be a Gloss, Matt or Satin finish. A texture can also be added if desired. The mould is made from silicone rubber, and the casting made by pouring resin into the mould in a vacuum chamber.
The result is high-quality bubble-free casting with blemish-free surface texture.
Vacuum Casting part properties
- Heat resistance
- Colours and tints
- Fire retardance
- Flexibility and rigidity
- UV stability
- Range of surface finishes
- Insert options
- Water clear
- Flexible polyurethane casting resin grades range
- Inserts can be moulded in
- Range of finishes from grades of spark texture, smooth matt and satin to a high gloss finish.
Process benefits
As well as being a highly effective method for producing small numbers of quality polyurethane prototype parts, this technology can also deliver parts with varying degrees of flexibility or rigidity in a wide range of colours and materials – as well as clear parts. Vacuum casting is used to produce parts before injection mould tooling is commissioned. Injection mould tooling can be costly and have a long production lead time. Therefore, using vacuum casting for your product development makes more than just financial sense.
In summary:
- Ideal for functional testing and/or marketing
- Cost-effective
- Low volume runs
- High quality
- Fine detail and accuracy
- Material properties similar to injection moulded polymers
- No requirement for expensive hard tooling.
Silicone Tooling
Silicone tools have a limited production life. The number of parts that can be produced from a single silicone tool depends on one or two factors (and often both):
- The polyurethane (PU) material used, and
- The geometry of the part being produced
A silicone tool running a general PU material simulating ABS will on average yield 20-25 parts; a flexible material in the lower Shore A range will yield 25-30 parts, and a material with a filled content will yield around 10 parts but could be a low as 5.
The geometry aspect is down to the part detail, normally within the “B” surface where clip features exist, which can cause the tool to degrade.
Some inserts may be required to hold certain features and will affect the price and lead time.
Once your order has been completed we will store the tooling for a period of 3 months. If the tool cannot produce any more parts then it will be disposed of as soon as the order is completed. You can request we store your tooling for longer than 3 months as long as it is before the order is completed.
In most cases, the master model used to create the tooling will have been destroyed during the tooling process.
Plastic material simulation
- ABS
- POM
- Elastomers (Range: 25 – 95 Shore A)
- Nylon including glass filled
- Polypropylene
Dispatch service levels
We offer a range of service levels for 3D Printing and CNC Machining.
We never compromise on quality, so these service levels are designed to help you meet tight timescales or economy budgets.
Finishing options
We offer a range of finishing options on 3D printed parts. Please visit our Finishing page for more information.
Take the tour
We encourage our customers to visit our prototyping bureau in Royston so we can show our full range of services and answer any questions you may have about your next project. If you would like to arrange a tour, please contact us.
Request a quote
Next day dispatch: we offer a next day dispatch service for SLA, SLS, FDM, Polyjet and Figure 4 3D printed parts. All final data for our Express Service Level is required by 4.30pm to guarantee next working day dispatch.
Other service levels: we also offer Standard (3-day dispatch) and Economy (8-day dispatch) service levels.
Quote requests: we process all quote requests and orders between 8.00am and 5.00pm on business days. Quote requests received between 8.00am and 4.00pm are usually responded to on the same day. This does, however, depend on the complexity of the requirement. Quote requests received after 4.00pm will be responded to on the following business day.
Express service level: for CNC Machined parts for dispatch in 3 working days, subject to criteria. All final data for our Express Service Level is required by 4.30pm to guarantee dispatch in 3 working days.
Other service levels: we also offer Standard (7-day dispatch) and Economy (12-day dispatch) service levels.
Quote requests: we process all quote requests and orders between 8.00am and 5.00pm on business days. Quote requests received between 8.00am and 4.00pm are usually responded to on the same day. This does, however, depend on the complexity of the requirement. Quote requests received after 4.00pm will be responded to on the following business day.
To request a quote for any of our other technologies/services, such as Vacuum Casting, Model Making and Laser Cutting, please complete this contact form.
