Vacuum Casting

Polyurethane vacuum casting is a specialized method for creating high-precision replicas of master patterns using cost-effective silicone molds and pourable casting resins. This process produces copies that match the quality of plastic injection molded parts but with significantly reduced time and cost.

Advantages Of Vacuum Casting

● Low-cost molds

● Molds can be produced in just a few days
● A wide variety of polyurethane resins are available, including options for overmolding
● Cast copies offer high accuracy with excellent surface texture
● Molds are durable and can produce 20 or more copies
● Ideal for engineering models, samples, rapid prototypes, and as a bridge to production

When to Use Vacuum Casting?

Product developers often choose vacuum casting when they need a small batch of production-quality plastic parts, typically between 10 to 20 pieces, without the lengthy lead time and financial investment required for plastic injection mold tools.

These parts are ideal for prototypes, display models, crowdfunding and trade show campaigns, testing new designs for fit and function, and serving as a bridge to larger production runs. In some cases, vacuum casting can even produce end-use parts, as the pourable casting resins closely replicate the properties of ABS, Nylon, PP, acrylic, and soft TPE rubber.

Materials

At Aikete Plast, the vacuum casting materials we use are two-part resins mixed right before being poured into the silicone mold. These resins are analogs to typical plastic injection molding materials, providing a similar look and performance.

We can replicate materials like polypropylene, ABS, nylon, acrylic, and various soft elastomers with different hardness levels. Additionally, we can incorporate glass fibers to enhance the stiffness of ABS and nylon, offering even more design flexibility.

Why Choose Aikete Plast for Vacuum Casting Services?

With many manufacturers offering vacuum casting services, selecting the right one is crucial to achieving the desired results. Here’s why Aikete Plast is the ideal choice for your vacuum casting requirements.

Exceptional Quality and Speed

Finishing Services to Enhance Your Product

Intelligent Quotations for Every Project

Design for Manufacturing Support and Remote Flexibility

Industry-Leading Material Verification and Testing Services

Vacuum Casting Process

Step1: Master Patterns

Patterns are 3D models from CAD designs, made via CNC machining or 3D printing. They should withstand temperatures up to 40°C. Master patterns can be provided or created, but 3D-printed patterns may differ from CNC ones due to tool limitations.

Step2: Making the molds

Casting molds are made by pouring liquid silicone around a master pattern in a casting box, then curing it for 12 to 24 hours. After curing, the mold is cut open to remove the master, leaving an exact negative shape of the original. The pattern must be prepared by sanding and priming.

Step3: Casting Copies

You can now pour your chosen casting resins into the empty cavity to produce a precise replica of the original. It is also possible to use multiple materials for overmolding. Silicone molds usually support producing around 20 copies of the master pattern.

Technical Guide for Vacuum Casting

Standard accuracy

The standard tolerance is ±0.15mm per 100mm, with maximum precision reaching up to ±0.05mm.

Maximum part dimensions

The vacuum equipment can accommodate molds with dimensions of 2.0m x 1.2m x 1.0m.

Minimum wall thickness

The minimum wall thickness is 0.5mm, with an optimal range of 1.5mm to 2.5mm to ensure proper mold filling.

Lifetime of the silicone mold

Typically, a mold can produce 20-25 copies. However, for high-quality parts, such as those with clear or complex structures, a mold may yield only 12 or even 10 parts.