The incredible versatility of vacuum casting

Vacuum Casting is a very popular process that can be used both for prototyping and production component manufacturing.

While it is typically used to produce highly accurate polyurethane prototype parts, the great popularity of vacuum casting can be attributed to its astounding versatility.

In fact, Vacuum Casting is one of the most versatile of all prototyping processes because of the very wide range of properties that can be produced in the part, and the applications for which the parts can be used.

The process uses a silicone rubber mould, which itself is made from a 3D printed master part made using SLA.

The properties of the resulting resin parts are closely comparable to those of the final product, making Vacuum Casting ideal for prototype part production, both for presentation and testing purposes, as well as small runs of production parts. The vacuum production element of the process produces a high quality bubble-free casting with a blemish free surface texture.

Why Vacuum Casting is the most versatile of all prototyping processes

#1 Materials used

Vacuum Casting parts are made using polyurethane (PU) resins, which are available in a wide range of grades offering different properties and durabilities.

#2 Range of materials that can be simulated

Using these PU resins, Vacuum Casting is used to accurately simulate a vast range of industrial materials including engineering polymers such as ABS, polycarbonate and polypropylene. The properties of glass filled nylon, elastomer rubber, as well as injection moulded and metal die cast parts can also be replicated.

At Prototype Projects we offer the following Vacuum Casting materials to simulate the following production materials and properties:

#3 The range of finishes that can be achieved

Because of the bubble-free finish produced by the Vacuum Casting process, a very high quality surface finish can be achieved. At the same time, any fine details and complex surface textures required from the master can also be reproduced.  A wide range of colours is possible due to the vast range of resin materials available.

#4 The range of properties that can be reproduced

The range of properties possible with Vacuum Casting is vast, from the quality of the part’s physical appearance to its mechanical, thermal and physical properties. The list of properties that can be achieved includes:

• Surface texture/finish
• Transparency/translucence
• Rigidity
• Flexibility
• Strength
• Hardness
• Temperature resistance
• UV stability

Typical materials that can be mimicked with Vacuum Casting include high performance production and engineering polymers such as ABS, polycarbonate polypropylene, nylon and elastomers.

#5 The range of applications the process can be used for

As would be expected with the materials and properties that can be reproduced with Vacuum Casting, the range of industry and product applications is also vast. to high quality consumer products is possible.

Common usages extend to components, trims, fixtures, fittings, lenses for the automotive and aerospace sectors, through to enclosures, housings and casings for consumer white goods and household products, to scientific and healthcare products in the pharmaceutical and medical sectors.

Other applications for Vacuum Casting include telecommunications, engineering and food production.

#6 The different stages of the product development process

Vacuum Casting’s versatility makes it an ideal process to use at all stages of the product design and development lifecycle. It can be used to create prototype parts, visual/presentational and marketing models, pre-production and pre-launch testing parts and, low-volume production parts.

#7 The range of sizes that can be produced

The range of parts available using Vacuum Casting depends only the specification of the part. At Prototype Projects the casting weight for our in-house Vacuum Casting machines ranges from just a few grams to 1.4 kg, with a maximum mould size of 450 x 470 x 400 mm. Larger size parts up to several kg in weight can be supplied – please request information.

#8 The quantities of parts that can be produced simultaneously

Typically Vacuum Casting is used for short batch runs of prototype parts for testing and assessment, or for low volumes of production parts. Most moulds are good for 20 – 40 parts before a new mould is required (the PU grade of material used has a big impact on tool life). However if larger quantities are required at the same time, more parts can sometimes be accommodated by casting multiple parts in the same mould.

GOT A VACUUM CASTING REQUIREMENT?

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