For small series
with big impact.

Vacuum casting is a copying technique used for the production of small series of functional plastic parts. Using two-component polyurethanes and silicone molds, vacuum casting is known for its fast production of high-quality prototypes or end-use products.

 

How does Vacuum Casting work?

Vacuum Casting begins by producing a master model, typically using Stereolithography or Laser Sintering, with a high-quality surface finish. Then a silicone mold is produced by casting silicone around the master copy, partially under vacuum to avoid air bubbles. After curing, the silicone mold is cut according to pre-defined parting planes and the master is removed, leaving a cavity to make copies.

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Why choose Vacuum Casting?

Silicone molding results in high-quality parts comparable to injection-molded components. This makes vacuum casted models especially suitable for fit and function testing, marketing purposes or a series of final parts in limited quantities. Vacuum Casting also lends itself well to a variety of finishing degrees, and we can match the finish you need for your parts.

 

Ideal applications for Vacuum Casting

  • Pre-launch product testing
  • Small series of housings and covers
  • Concept models and prototypes

Choose Vacuum Casting
When You Need…

  • Fast and cost-effective low-volume production series
  • Prototype series
  • Conventional manufacturing plastics
  • Large parts up to 1900 x 900 x 750 mm
  • Multi-material parts via overmolding

Technical Specifications for Vacuum Casting

Standard lead time Up to 10 copies within 10 days.
Standard accuracy ± 0.3% (with lower limit on ± 0.3 mm on dimensions smaller than 100 mm)
Minimum wall thickness To ensure that the mold is filled properly, a wall thickness of at least 0.75 mm is necessary. For best results, we recommend a wall thickness of at least 1.5 mm.
Maximum part dimensions The size of the mold is limited by the dimensions of the vacuum chamber (1900 x 900 x 750 mm) and by the volume of the product (maximum volume: 10 liters).
Typical quantities Up to 25 copies per mold (depending on the mold’s complexity and the casting materials).
Surface structure High-quality surface finish comparable to injection molding.

Materials for Vacuum Casting

We offer an exceptional range of 26 carefully selected polyurethanes that are similar to rubber, PP, ABS and PC. These materials provide an outstanding variety of properties, and offer the possibility to match colors and cast transparent components. If you are looking for a specific finish, our skilled post-production team for Vacuum Casting will match your requirements.

Contact us for more detailed information, to find the material most suitable for your project.

For more material properties and technical specifications, please visit our Resource Center to download the material datasheets.

Finishing Degrees for Vacuum Casted Parts

Finishing Gates, runners and flash removal Sandblasting Primer Manual smoothing Coating/Color
Basic      
Pigmented in black, unless specified otherwise
Natural      
No added pigment; original color of PU resin is visible
Sandblasted    
Pigmented in black, unless specified otherwise
Normal A-Side    
Black matte paint (textured) on A-side
Smooth A-Side    
Black matte paint (smooth) on A-side
Ready to Paint
Primer in white or gray
 
Soft Touch
On A-side only, unless specified

Soft touch paint on A-side according to specified RAL color
Colored in Mass      
Mass pigmented according to specified RAL color
Matte Paint
On A-side only, unless specified

2K PU matte paint according to specified RAL color
High-Gloss Paint
On A-side only, unless specified

2K PU glossy paint according to specified RAL color
Fine-Texture Paint
On A-side only, unless specified

2K PU matte paint according to specified RAL color, fine texture
Spatter Paint
On A-side only, unless specified

2K PU paint on A-side according to specified RAL color, coarse texture with spatter finish
Satin Paint
On A-side only, unless specified

2K PU satin paint according to specified RAL color
Translucent      
Can be slightly colored if desired
Transparent        
Metal Plating    
Metal plated