Vacuum Casting Services

The use of YD polyurethane vacuum casting technology ensures the precision and durability of each casting. It is of reliable quality and has a short production cycle.

  • Ability to produce large parts
  • Highest precision to reach ±0.05 mm
  • Color and texture can be customized
  • Up to 20 parts in 15 days or less
  • 24/7 engineering support
Vacuum-Casting
Vacuum-Casting
Get an instant quote

STEP | STP | SLDPRT | IPT | PRT | SAT files

 All uploads are secure and confidential.

What is Vacuum Casting

Vacuum casting is a manufacturing process used to produce small quantities of high-quality plastic or rubber parts. The process involves creating a silicone mold from a master model (often 3D printed or CNC machined) and then using vacuum pressure to fill the mold with liquid materials such as polyurethane or silicone. This process is ideal for prototyping, short-run production or detailed parts with complex geometries. It offers a cost-effective alternative to injection molding with high accuracy, surface quality and the ability to replicate fine details from the master model.

At YD, we are improving the polyurethane vacuum molding process by ensuring that dimensional shrinkage of parts does not exceed +0.15% within 30 inches, while maintaining tight tolerances for complex designs. Our services are highly customizable and can meet the needs of parts with transparent, color-matched or special surface finishes, such as parts that require electromagnetic interference shielding. We also integrate various inserts into the molding process to enhance functionality.

Get an instant quote
Vacuum-Casting-Services

Vacuum Casting Solutionsl Solutions

Prototyping

Rapid Prototyping

Our Rapid Prototyping service delivers rapid sheet metal parts to help you validate your design and perform functional testing faster than ever before. It’s perfect for making adjustments and achieving optimal results for your final product, with a fast 1-3 week lead time and economical cost per part.

Learn More
Production

Low and High-Volume Production

Leverage our versatile sheet metal fabrication services to quickly adapt to market fluctuations. We specialize in handling custom orders, providing seamless scalability and on-time delivery. As production volumes increase, the cost per unit decreases dramatically.

Learn More

Available Materials

Vacuum Casting Materials

At YD, Urethane resins are polymers with a wide range of properties and applications. YD offers various urethane materials to meet your applications, materials with certain properties are similar to engineering production plastics, such as ABS, PMMA, PC, PP, PA, and so on. Molded parts can vary from transparent, translucent to colored, and from soft rubber to hard plastic. Different materials include impact resistant, high temperature resistant (120℃) or fire resistant (UL94-V0), glass-filled resins, and silicone of different hardness.

Advantages of Vacuum Casting

  • High accuracy. Vacuum casting makes parts that are very accurate.
  • Surface quality: It provides excellent surface finishes, so there is no need for post-processing.
  • Inexpensive for small quantities. Ideal for short runs or prototypes, as it avoids the high setup costs of injection molding.
  • Works with different materials. Many different materials can be used in the process, including flexible rubbers, rigid plastics, and transparent materials.
  • Fast turnaround. This process is ideal for rapid prototyping and design validation.
  • Complex shapes: The process can make copies of complex designs, including ones with undercuts and thin walls.
  • You can customize it. It’s easy to match colors and add different hardness levels to a single part.
  • Vacuum casting is a flexible and efficient way to make high-quality prototypes and low-volume parts.
Vacuum-Casting

Working Of Vacuum Casting Process in Rapid Prototyping:

We can understand the working of vacuum casting in the prototyping process in three easy steps:

Master Patterns 1

The vacuum casting starts with a prototype, the master pattern. Engineers often use 3D printing or CNC machining to make these patterns because it’s fast. These methods let engineers make changes early if needed.

Preparing Molds 2

When the patterns are ready, they are placed in a casting box, which is later filled with liquid silicone. It’s then cured in an oven for several hours, the silicone hardens, and the casting box is removed. The mold is then cut to remove the pattern, leaving an empty cavity with a copy of the original design.

Vacuum Casting 3

To make copies of the master pattern, the mold must be released with a feed tube leading into the cavity. Liquid urethane resin is then poured into the mold and held in a vacuum chamber. The sole purpose of the vacuum is to remove the air from the cavity and force the resin into the entire volume. The mold is then heated in an oven and the resin is cured. A perfect copy of the original design is obtained when the mold is reopened.

Curing and Part Removal 4

The resin is allowed to cure within the mold. After curing, the part is removed from the mold, which can typically be reused to produce multiple copies.

Finishing Touches 5

The final step involves cleaning and finishing the cast parts to achieve the desired surface texture and detail, and applying any necessary paint or coating.

FAQs

Choosing polyurethane vacuum casting over 3D printing offers these key benefits.

  1. Better material properties: Polyurethane is more durable, flexible, and resistant to wear and chemicals.
  2. Superior surface finish: Vacuum casting provides smoother surfaces with less post-processing.
  3. Cost-effective for small batches: More economical to produce multiple parts compared to 3D printing.
  4. Consistent Replication: Provides consistent parts with accurate dimensions.
  5. Broader material options: Supports a wider range of materials, including flexible and rigid types.
  6. Color and transparency: Easily produce parts in multiple colors and transparent finishes without additional steps.

Choosing polyurethane vacuum casting over injection molding provides these advantages:

  1. Lower Initial Costs: Cheaper and quicker mold production.
  2. Faster Turnaround: Ideal for rapid prototyping and small batches.
  3. Cost-Effective for Low Volumes: More economical for short runs under 100 parts.
  4. Easier Design Changes: Modifications are faster and cheaper.
  5. Material Flexibility: Supports a wider range of materials.
  6. Handles Complex Designs: Better suited for intricate geometries.
  7. Shorter Lead Time: Faster overall process for small production needs.
 

Key design considerations for vacuum casting include:

  1. Part Geometry: Ensure smooth transitions, rounded edges, and minimal undercuts to facilitate mold release.
  2. Wall Thickness: Maintain uniform thickness to avoid warping and ensure even material flow.
  3. Draft Angles: Incorporate draft angles for easier part removal from the mold.
  4. Tolerance and Shrinkage: Account for material shrinkage, typically 0.15-0.25%, to ensure dimensional accuracy.
  5. Ventilation: Design with proper vents to avoid air entrapment and ensure complete material filling.
  6. Mold Lifespan: Consider that silicone molds have a limited number of uses (usually 20-25 cycles).

These factors help optimize part quality and production efficiency.

During vacuum casting, the mold is typically held together by an external mold box or a rigid frame, which supports the silicone mold and maintains its shape under vacuum pressure. Clamps or fasteners are also used to securely close the mold halves, ensuring proper alignment and preventing leakage of the casting material during the process.

Get an instant quote