Vacuum Casting

Vacuum casting produces small series of plastic parts using silicone molds made from a master pattern. The master (typically produced by SLA or CNC machining) is used to cast a silicone mold. Liquid polyurethane resin is cast into the mold under vacuum, eliminating air bubbles and reproducing fine surface detail.

Each silicone mold yields 20-25 parts before requiring replacement. The process is suitable for small series requiring surface quality and material properties close to injection molding, without the cost of hard tooling.

What Sets Us Apart

Engineering-Led Manufacturing

In-house master pattern production

SLA and CNC machining for high-accuracy masters before casting.

Short lead time

7-14 days from approved design to delivery.

Up to 25 parts per mold

no hard tooling investment required.

Material range

30+ PU resin types simulating ABS, PP, PC, rubber, and engineering elastomers.

Our Vacuum Casting

Standard Vacuum Casting

Cast polyurethane parts in silicone molds at surface quality close to injection-molded parts. Suitable for appearance prototypes, functional testing, and bridge production before tooling.

Clear and Transparent Casting

Water-clear PU resins produce optically transparent parts. Suitable for lens covers, display windows, light guides, and aesthetic components where clarity matters.

Overmolding: Dual Material

Rigid and flexible resins combined in one part. Suitable for soft-grip handles, two-material enclosures, and ergonomic assemblies.

Textured Surface Casting

Custom textures applied to the silicone mold replicate leather grain, surface patterns, or fine detail. Suitable for consumer products, automotive interior trim, and ergonomic parts.

Our Process

STEP 1

Master Pattern

A high-accuracy master is produced by SLA 3D printing or CNC machining.

STEP 2

Mold Making

The master is suspended in a mold box and liquid silicone poured around it; cured for 8-16 hours.

STEP 3

Resin Selection

PU resin is chosen to match the target mechanical properties and surface finish.

STEP 4

Vacuum Casting

Resin is poured into the mold under vacuum and cured at 60°C.

STEP 5

Demolding

Cast part removed after curing; gates and flashing trimmed.

STEP 6

Finishing and Dispatch

Paint, primer, or surface treatment applied if required. Parts inspected and shipped.

Materials

Plastics

Material	Key Properties	Suitable Applications
ABS-like PU	Rigid, good impact resistance, sandable	Housings, brackets, functional prototypes
PP-like PU	Slightly flexible, living-hinge capable	Clips, caps, snap-fit components
PC-like PU	High impact, heat resistant	Enclosures, structural housings, covers
Rubber-like PU (Shore A 40-80)	Flexible, elastic, tear resistant	Seals, grips, overmolded soft components
Nylon-like PU	Tough, slightly flexible	Snap fits, gears, load-bearing functional parts
Transparent PU	Optically clear, scratch resistant	Lenses, windows, display covers
High-Temp PU (HDT >120°C)	Heat resistant	Under-hood parts, heat-exposed components
Glass-Filled PU	Higher stiffness than standard PU	Structural brackets, dimensionally stable parts