Vacuum Casting

Vacuum Casting (Urethane Casting)

A bridge between prototyping & production Silicone Tooling/Vacuum Casting/Plastic Urethane Parts

Vacuum casting in conjunction with silicone tooling is the ideal way to create production-quality prototypes and end-use parts. It’s a quick, cost-effective solution to produce high-quality, cosmetic, and functional parts in production-like materials.

At Formero, we start the process with a master pattern made using 3D printing or machining depending on tolerance needs. We then use that master to make a silicone rubber mould. We pour liquid urethane material under a precise vacuum into the mould. Once the urethane cures the part is removed and finished.

Because of vacuum casting’s ability to produce parts with textures quickly, it is a process worth investigating. Formero can make the vacuum moulding and casting process a straightforward experience for you!

Vacuum Casting Applications

Vacuum casting finds versatile applications across various industries, offering tailored solutions for specific production needs. From creating presentation models to facilitating low-volume production runs, vacuum casting proves instrumental in achieving high-quality results efficiently and cost-effectively. Let’s explore some key applications where vacuum casting excels:

  1. Presentation models: Vacuum casting produces finely detailed models perfect for showcasing product concepts during presentations and exhibitions.
  2. Prototyping: Vacuum casting expedites the prototyping phase by creating high-fidelity models for testing and iteration before mass production.
  3. Low-volume production run: Vacuum casting enables cost-effective manufacturing of small batches of parts with consistent quality, ideal for niche markets and custom products.
  4. Replacement components (e.g. vintage automotive parts): Vacuum casting replicates rare or obsolete parts with precision, serving as a lifeline for restoring vintage vehicles and machinery.

Black plastic housing, made for car switches.

Red and clear car brake light cover

Advantages of our Vacuum Casting Services

The vacuum casting process boasts a wide array of industrial applications, commonly utilised for low-volume production of prototypes or production parts. This production technique offers distinct advantages over alternative methods of rapid prototyping and manufacturing.

  • Precise detailing: One notable advantage of the vacuum casting process lies in its capability to produce parts with intricate detailing. Utilising a 3D printed master model, the process effectively replicates fine details, ensuring fidelity in the final cast.
  • Cost-effectiveness: Another significant benefit of vacuum casting is its cost-effectiveness. In comparison to other rapid prototyping methods like CNC machining, vacuum casting requires fewer resources and time. With the production of a mould taking only a few hours and being reusable multiple times, the process significantly reduces expenses. In contrast, CNC machining demands costly tools and materials.
  • Dimensional accuracy: Vacuum casting yields parts with exceptional dimensional accuracy. Ensuring precise fits without the need for additional post-processing steps such as sanding or drilling, this process enhances overall efficiency in manufacturing.
  • Design flexibility: Vacuum casting affords a high degree of design flexibility. Leveraging the versatility of 3D printing, virtually any geometry can be realised, facilitating the production of parts that would otherwise be challenging or impractical using traditional manufacturing methods.

Materials Available

  • TPE-LIKE || SHORE A DUROM – 25A, 40A, 50A, 60A, 70A, 80A, & 90A (+/- 5)
  • TPU-LIKE || SHORE A DUROM – 25A, 40A, 50A, 60A, 70A, 80A, & 90A (+/- 5)
  • HIGH HEAT 120°C

Clear plastic part for bike light

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