Vacuum Casting Technology

Optimize batch production for speed and cost-efficiency by leveraging diverse material options

What is Vacuum Casting?

Vacuum casting also known as Polyurethane Casting is a manufacturing process that involves creating plastic or resin parts using a silicone mold under vacuum conditions. It is commonly used for prototyping, small-batch production, or replicating complex parts with fine detail. It is ideal for producing high-quality parts with intricate details, especially when small batches are needed. It offers benefits like quick turnaround times, a range of material options, and the ability to replicate complex geometries without extensive tooling costs.

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Steps involved in Vacuum Casting:

Master Pattern Creation: The process begins with a master pattern, which can be made from various materials such as metal, plastic, or even 3D printed. This pattern is a precise replica of the final product and is used to create the silicone mold.
Silicone Mold Preparation: A silicone rubber compound is poured over the master pattern, often within a rigid frame or box. This compound is allowed to cure, forming a flexible silicone mold around the master pattern.
Master Pattern Removal: Once the silicone mold has cured, the master pattern is removed, leaving a cavity with the exact shape of the pattern. This cavity is where the casting material will be poured.
Setting Up the Vacuum Chamber: The silicone mold is placed in a vacuum chamber, along with the chosen casting material (usually a type of resin or polyurethane). The vacuum chamber is sealed to prepare for the casting process.
Applying Vacuum and Pouring Resin: A vacuum is applied to the chamber to remove air bubbles and reduce pressure, ensuring a smooth, even flow of resin into the mold cavity. The resin is then poured into the silicone mold while the vacuum is still applied, allowing it to fill all parts of the mold without trapping air bubbles.
Curing and Demolding: The resin-filled mold is left to cure (harden). Depending on the type of resin used, this can take anywhere from a few minutes to several hours. Once the resin has fully cured, the silicone mold is carefully peeled away to reveal the cast part.