Vacuum casting is an economical solution to casting for small batches of polyurethane plastic parts
Rapid prototyping to manufacturing
What is vacuum casting
vacuum casting (also known as urethane casting) is a cost-effective manufacturing technology suitable for low volume production of plastic parts that accurately simulates the molding effect of the final product. Silicone rubber molds are usually used. These molds are based on master molds made by CNC machining or SLA (stereolithography) technology, which can finely replicate complex details and textures to ensure that each casting has a consistent look and feel. Through this process, you can get parts that are close to actual production, including similar mechanical properties, precise wall thickness control, customized color options, and high-quality surface finish.With many years of experience in vacuum forming and custom silicone molds, Brightstar can produce high-quality and inexpensive plastic parts with fast turnaround, which is very suitable for advanced prototypes, functional testing, concept verification and display demonstrations. Polyurethane casting parts can be manufactured from a few to hundreds of parts as needed.
2015
ISO 9001 CERTIFIED
100+
CNC machines
10K+
CNC machined parts/ month
100+
Plastic & metal materials
Advantages of vacuum casting
Silicone molds are inexpensive
cast polyvacuum parts are made from inexpensive molds without investing in expensive and time-consuming metal tools. This is a cost-effective way to make high-quality prototypes and small batches of parts.
Fast delivery
vacuum casting has a short production cycle from mold making to finished product. Up to 50 functional -cast polyvacuum parts can be produced in 10 to 15 days.
Repeatability
Silicone molds can be reused approximately 20 times, which means that the same product can be produced 20 times.
Color can be added
Colored pigments can be mixed into the resin to make the product have a variety of color options.
Excellent surface finish
Because the vacuum film reduces bubbles and voids, the material density is improved, which can make the material surface tighter and better surface effect.
How vacuum casting Works
The vacuum casting process is divided into three steps: master mold, molding, and casting.
Casting Process
Brightstar's standardized operating procedures ensure accurate replication of parts and consistent mechanical properties. Our vacuum casting technicians control all operational parameters:
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Making Silicone Molds
The casting mold is made from liquid silicone resin, also known as RTV mold. The silicone rubber has excellent chemical stability, self-release properties, and flexibility, and because it has minimal shrinkage, it can effectively transfer fine details from the master model to the mold.
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Master Model Creation
The quality of the cast polyvacuum parts depends on the quality of the master model. When you need to maintain strict tolerances, glossiness, or even optical clarity, it is best to process through CNC machining.
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Why cooperate with Brightstar's in custom machining services?
Quality has always been the guideline for Brightstar Behavior, which is the biggest reason for customers to choose and trust Brightstar and maintain stable cooperation. We strictly follow the ISO 9001 certified quality management system standards and have also obtained the iso 9001 2015 certification. Through rigorous inspection methods such as IPQC, FAI, and FQC, a series of quality inspections and controls, and the use of advanced detection tools, we ensure that the precision and quality of each product meet or even exceed customer requirements.
High Quality
Diversity in material selection and surface treatment
Cost-effectiveness
High customization
Fast delivery capability
The ability to provide comprehensive solutions
Application of CNC machined parts
Our Superior vacuum casting rapid prototyping examples
Materials for vacuum casting
Polyvacuum resin is a polymer with a wide range of properties and uses. Brightstar offers a variety of polyvacuum materials to suit your application, including Hei-Cast from Japan and Axson from France, while materials with certain properties similar to engineering production plastics, such as ABS, PMMA, PC, PP, PA, silicone rubber poxy and epoxy, polyvacuum, etc. -cast parts can range from transparent, translucent to colored, from soft rubber to hard plastic, and a variety of materials including impact resistance, high temperature resistance (130°C) or fire resistance (UL95-V0), glass-filled resins and silicones of varying hardness.
CNC Metal Machining
We can manufacture more than 100 kinds of metal materials. Our CNC metalworking technology can ensure tight tolerances, fast delivery cycles and meet the most difficult manufacturing needs, whether in prototyping or final product production.
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CNC Plastic prototyping
CNC machining of plastic materials is quite extensive, with over 40 types of engineering-grade plastics that we can process, achieving excellent product structure and functionality, and are capable of undergoing mechanical testing.
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Surface finish of vacuum casting
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Matte/Frosted | Parts have a smooth, satin-like finish due to the master pattern being bead-blasted matte. Transparent and translucent parts with this finish will appear frosted. Matte finishes are helpful for handheld and high-touch areas as it reduces fingerprint visibility. |
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Semi-gloss | Semi-gloss finishes include some sheen but not high reflectivity. Semi-gloss finishes are between high-gloss and matte, resulting in a smooth, easy-to-clean surface. |
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gloss | A highly reflective glossy finish requires polishing the master pattern before making the mold. The high gloss has a high sheen and will have the highest transparency for transparent parts. High gloss is helpful for cosmetic models, cleanable surfaces, and lenses. |
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Texture | Texture is applied via paint and manual techniques to the master pattern before making soft tooling. Texturing is useful for high-use surfaces, like handles, where the small raises and reliefs improve the grip and reduce fingerprint or scuff marks. |
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Customized | Brightstar can provide additional processing, including secondary finishes, painting, and more. |
Quote Now to Start Your Vacuum Casting Project
Common Vacuum Casting Applications
Advanced Prototyping;Low-Volume Production;Market Testing
Surface roughness level comparison and application
International Marking
Rz
Ra
Surface Shape Characteristics
Processing Methods
N12
200
50
Clearly visible tool marks
Sawing, rough turning, rough milling
N9
25
6.3
Visible tool marks
Cold drawing, fine turning
N6
6.3
0.8
Identifiable tool mark direction
Grinding, diamond turning tool finishing
N3
0.8
0.1
Matt gloss finish
Grinding, polishing, fine grinding
Put your parts into vacuum casting production now
01
Upload your CAD file
Click on the quote button and upload the product drawing to Brightstar to provide a quote for your project
02
DFM analysis and quote
Brightstar will send the quote and manufacturing solution design within 8 hours according to the email address you left
03
Start Production
After the order is confirmed, production will be carried out according to the CAD drawing
04
Get Your Parts
You will receive your product, prototypes and parts will be produced within a few days and delivered directly to you by international express. We ensure that your order is accurate and arrives quickly.
Vacuum Casting Technology Guide
Standard accuracy
The standard tolerance is ±0.15mm/100mm, and the highest accuracy can reach ±0.05mm.
Maximum part size
The vacuum equipment can accommodate molds with specifications of 2.0M*1.2M*1.0M.
Minimum wall thickness
The minimum wall thickness is 0.5mm, and the optimal is 1.5mm to 2.5mm to ensure that the mold is fully filled.
Surface texture and other features
Vacuum casting has a variety of color options, including color matching, black, natural color (no pigment), clear color (no color), texture, painted, coated, clear polished, inserted and overmolded.
Life of silicone molds
Typical quantities per mold can reach 20-25 parts. If the part requires high quality, such as clear or complex structures, usually only 12 or even 10 castings can be produced from one mold.
Standard delivery time
Depending on the complexity and quantity of the mold, up to 50 parts can be produced in 7 to 10 days.
FAQ about vacuum casting
How much does vacuum casting cost?
The cost of vacuum casting depends on a variety of factors, including the complexity of the mold, the cost of the material, the equipment and labor required, etc. Generally, vacuum casting costs more than ordinary casting, but it is worth it in some applications because it can provide higher quality castings.
What is the difference between vacuum casting and ordinary casting?
Ordinary casting may not completely remove bubbles from the material, resulting in defects on the surface of the casting. vacuum casting can effectively remove bubbles and improve the quality and details of the casting by performing it in a low-pressure environment.
What industries are vacuum casting suitable for?
vacuum casting is widely used in multiple industries, including:Automotive industry: used to make prototypes and certain functional parts. Medical industry: used to make precision medical devices and components. Aerospace: used to make lightweight, high-strength parts.Consumer products: used to make toys, electronic product housings, etc.
How are vacuum casting castings post-processed?
Grinding, polishing, painting or other surface treatments are performed as needed. For functional parts, performance testing and verification may be required.
vacuum casting services
Fast, short run production option for small batches of plastic prototype parts.
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