Vacuum casting is the technology we use to produce plastic parts made from high-quality polyurethane in short series –
20-500 pieces in a span of a few days.
Advantages of Vacuum Casting
The main advantage of this approach is the lack of need to produce tools and metal matrices, which is a more expensive and slower process. At the same time vacuum casting contributes to achieving an impeccable outlook for the end product. The way the items or elements are produced through casting strengthens them and makes their properties easy to predict. A broad range of materials is available to satisfy almost every requirement. You can have products resembling ABS, Nylon, PP, and other polymers. The products can be flexible, noncombustible, and transparent.
From one matrix, depending on the element, 10 to 30 pieces can be produced before it starts degrading.
On the way to producing the silicon matrix, we first need to 3D print the prototype with the most accurate technology.
Process
The preparation stage of the vacuum casting process takes a short time, usually about three or four days. On the way to producing the silicon matrix, we first need to 3D print the prototype with the most accurate technology. Here is where we look to achieve the perfect outlook, and optionally the element can be painted or varnished to achieve the desired appearance. This process takes about 2-3 days, and then we start making the matrix, which usually takes another day. So you can get the first 10-15 pieces in less than a week.
Detailed Steps
1. Preparing a 3D model of the element to be produced (not necessary if you have the physical sample to follow) 2. Printing of the prototype with high quality and appearance (not needed if you have the physical sample to follow) 3. Treatment of the prototype, if required – painting, varnishing, etc., to achieve the desired appearance 4. Pouring the silicone matrix into a special machine 5. Pouring the polyurethane into the silicone matrix in a special machine in which it solidifies 6. There is an optional over-molding of inserts and pins, other materials like rubber might be added too.
Outcome
From one matrix, depending on the element, 10 to 30 pieces can be produced before it starts degrading. Usually, once we have it, we can immediately start pouring the details into it, and in the span of a day we can provide around 10-15 pieces. If more details are needed in a short time, we can always start the production with more than one matrix.
