Vacuum Casting
Vacuum casting is the ideal manufacturing method for small production of high quality parts
We offer vacuum casting in the following materials with a variety of hardness.
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• ABS (Acrylonitrile butadiene styrene)
• PC (Polycarbonate)
• PP/PE (Transparent)(Polypropylene/Polyethylene)
• PA (Nylon or Polyamide)
• PU/TPU (range from Shore 30A to Shore 95A) (Polyurethane / Thermoplastic Polyurethane)
To assist you with a material selection, we have summarised a few important material properties on the table below.
Important Material Properties
A little more info
If you don’t find the material you need, please contact us at [email protected] to discuss your product requirement and we will do our best to source it.ABS
• ABS type prototype parts
• Easy processing
• Excellent mechanical properties
• Good heat resistance up to 100°C
PMMA
• Used by casting in silicone moulds for making transparent prototype parts until 10 mm thickness: headlights, glazier, any parts which have the same properties as PMMA, crystal PS, MABS etc.
• High Transparency
• Easy polishing
• High reproduction accuracy
• Good UV resistance
• Easy processing
• Fast demoulding
PU/TPU
• Excellent UV stability
• Excellent resistance in grease, fuels, solvents, oils
• Black, light yellow or transparent
• Outstanding general impact strength, not breakable
• High elongation
• Easy processing
• Good flexibility
PP8045 / PE8045 (Polyurethane Resin)
• Ideal for high impact applications (variable hardness available depending on mixture %)
• Commonly used in-snap fit applications
• Pigmentable
If you don’t find the material you need, please contact us at [email protected] to discuss your product requirement and we will do our best to source it.
Our Machine Capabilities
Machine Specs
- Chamber size: 1200x1600x1000mm
- Vacuum pump: 4kW (200m3 / h)
- Vacuum degree 100KPA
- Vacuum Capacity: 8L, 4L, 1 set of for each (double system)
- Mixing methods: Automatic
- Injection method: Automatic
- Tank: stainless steel plate
Machine Specs
- Chamber size: 650x800x600mm
- Vacuum pump: 2.2kW (100m3 / h)
- Vacuum degree: 100KPA
- Vacuum capacity: 4L
- Mixing method: Automatic
- Injection method: Automatic
- Tank: Stainless steel plate
Examples of vacuum casting products
Frequently Asked Questions
1
What is vacuum casting?
Vacuum casting is a modern advanced manufacturing technology, a 3D printing sibling that can contribute to product development.
The main application is on small batches and prototypes where geometries are complex, and there is a high possibility of air entrapment. The name of this method is derived by the use of vacuum which pushes a specific mean of liquid into a silicone mould. It is a relatively new process, and it belongs in the wider additive manufacturing family to generate a part.
2
How does vacuum casting work?
The process requires
➢ a master 3D CAD model which can be produced using stereolithography (SLA) or laser sintering or
➢ a physical model in high quality with excellent surface finish that can be used as a master model instead
Model Immersing
The printed model or the master physical model is then immersed into a two-piece liquid silicone rubber. A high-pressure vacuum is then used to remove the remaining air and finally form the mould.
Mould Curing
The next step includes the curation of the mould in a high-temperature oven in order to improve its mechanical properties, strength and durability. That process is called mould curing.
Once the curing process is complete, the parts are removed from the oven, and a gap has been formed in the centre of the cured mould. This gap has the exact shape and dimensions of the master part that been used at the beginning of the process.
Adding resin and a vacuum chamber
The mould is then filled with the required material and placed in the vacuum casting chamber. This step is critical as the trapped air bubbles will be removed from the mould.
Post Curing of the part
This is the final step where the mould is cured in high temperatures for the last time. The silicone mould will be removed from the produced part, and it can be used again to make more parts of the same geometry and shape.
The part can then be painted or decorated as required.
3
Vacuum casting applications
The high quality of the produced parts, the easiness to manufacture as well as the minor need for post-process, make vacuum casting a competitive method among the additive manufacturing technologies. Below is a list of applications where vacuum casting is most commonly used:
➢ Small batch of products with complex geometry
➢ Prototypes for visualisation purposes
➢ For design validation prototypes
➢ For packaging, cases, housings
➢ Fit for function tests
➢ Marketing purposes
4
How this technology can benefit your project or production?
Investing in vacuum casting can benefit a company which deals with small production batches or prototypes. The advantages of using vacuum casting are:
a) High product quality
Due to the nature of the process, it is possible to choose from a variety of polyurethane resins, and the hardness and flexibility can be carefully be selected prior to the production of the part. The casted finished object can then be easily painted or can be kept crystal clear without any subsequent post-processing.
b) High precision and very good surface finish
The use of liquid silicone during the process ensures that the resulted part will have excellent appearance and surface finish. This is a significant advantage, especially for those who want to replicate a small number of geometrically complex parts achieving a uniform finish and appearance.
c) Production cost can be competitive
The silicon use also guarantees that the cost will be much lower compared to other manufacturing techniques such as CNC or injection moulding. It also takes less time to produce a part than other methods such as 3D printing.
Vacuum casting in conclusion
This method is far more economical than injection moulding and can be used as a good and much quicker alternative to 3D printing. From a cost and time point of view, vacuum casting is the preferred method for producing prototypes or small batches (e.g. 50-100 parts). It also combines all those manufacturing benefits that makes this process really attractive to customers.