Vacuum Casting Small Batch Production And ABS Plastic Rapid
Prototyping Parts
Vacuum Casting :
Vacuum casting is a swift, budget-friendly method for replicating
top-notch plastic parts, akin to injection-molded items. It employs
dual-component polyurethanes and silicone molds crafted from a
3D-printed prototype. This approach is ideal for testing fit and
function, marketing needs, or producing limited runs of final-use
components.
1. Rapid prototyping
and full-scale production
2. Used in over
20 countries
3. ISO 9001 accredited
The advantages of Urethane Casting:
- Suitable for Small Production Runs
- Achieves Consistent Self-Colored Parts
- Minimal InitiaInvestment Required
- Delivers Production-Quality Components
- Wide Array of Material Options
- Enables Creation of Rubber-Like Parts and Over molds
Urethane Casting Tolerance Guidelines:
| Maximum build dimensions | The size of the mold is limited by the dimensions of the vacuum
chamber (1,900 x 900 x 750 mm) and by the volume of the product
(maximum volume: 10 liters). |
| Standard accuracy | ±0.3% (with a lower limit on ±0.3 mm on dimensions smaller than 100
mm). |
| Minimum wall thickness | At least 0.75 mm to ensure the mold is filled properly; for best
results, wall thickness of at least 1.5 mm is recommended. |
| Surface structure | High-quality surface finish comparable to injection molding. |
Size limitations for Vacuum Casting:
Requirement
|
Specifications
|
Maximum part dimensions
|
1650 x 750 x 800 mm
|
Minimum wall thickness
|
0.35 mm (recommended wall thickness 0.35 mm-1.6 mm)
|
Duplication quantities
|
100-200 copies (depend complexity of the mold and casting
materials)
|
Vacuum Casting Process
Creating polyurethane vacuum cast parts involves three main steps:
master pattern creation,
mold fabrication, and part casting.
1. Master Pattern Creation:
Crafting patterns from your CAD designs is the initial step. These
3D solids are made through CNC machining or 3D plastic printing
like SLA/SLS. You can provide patterns or let us create them.
Patterns should endure up to 50°C heat.
2. Mold Fabrication:
Liquid silicone forms the casting molds. It's poured around the
master pattern within a casting box, cured in an oven for 15 hours.
Afterward, the mold is opened, and the master pattern is removed,
yielding a negative cavity mirroring the original. Our silicone molds typically yield around 25 copies of the master
pattern.
Our Vacuum Casting Services
Experience high-quality production parts with Vacuum Casting, also
known as Urethane or Polyurethane casting. At HLH, we offer a vast
selection of plastic materials and can cast parts ranging from
small headphones to large 2-meter car bumpers. Skip the lengthy
lead times and tooling costs – choose Vacuum Casting for efficient
solutions.
Our Capabilities
|
Description |
Maximum build size
|
1.9 x 1.6 x 1.5 m |
Typical mould life |
10 – 25 parts
|
Materials
|
Wide range of thermoplastics, rubbers, transparent resins, etc.
|
Lead time
|
From as fast as 7 days |
How does vacuum casting work?
The process involves 3 main stages:
- Building a master model
- Creating the silicone tool and
- Producing the parts
Building a master model:
To achieve precise results in vacuum casting, start with a
top-notch master model. Crafted via 3D printing or CNC machining,
it's meticulously refined for ideal surface texture and detail
replication.
|  |
Creating the silicone mould tool:
Create precise silicone molds by encasing the master model in a
casting box filled with liquid silicone. Maintain a 40°C
temperature for 8-16 hours until the silicone sets. Once cured, cut
open the mold to reveal a perfect fit for your master model. |  |
Producing the parts:
Fill the hollow mold with polyurethane (PU) resin through a funnel
to ensure even distribution and prevent air bubbles. Seal the mold
and let it cure at 70°C in a casting machine. After cooling, remove
the shaped material, and perform any required post-processing.
Typically, this process can be repeated 10-20 times before the
mold's shape starts to deteriorate, affecting accuracy.
|
|
Why Choose JYH- precision for Urethane Casting Parts Services?
In the realm of vacuum casting, a multitude of manufacturers are
available for selection. Opting for the correct one holds
paramount importance to achieve your anticipated outcomes. Consider
the following factors that make JYH an ideal
choice for your vacuum casting requirements.
- Outstanding Quality and Rapid Performance
At JYH Precision, we believe that quality and speed should go hand
in hand. Our approach combines extensive industry expertise with
cutting-edge tools and technologies, enabling us to provide
top-notch vacuum casting services within tight timelines (usually 5
to 7 days). | - Enhancing Your Product with Finishing Services
Vacuum casting is just a part of our capabilities. we provide an
array of supplementary finishing services that contribute to
bringing your product to its full potential. These services
encompass machining, media blasting, printing, painting, and
beyond. |
- Smart Quotes Tailored to Your Every Project
We recognize that your requirements are distinct, and unnecessary
expenses are undesirable. Hence, we refrain from imposing minimum
order volumes or dollar values for our vacuum casting services. we
ensure swift and precise quotes within 1 hours or less for almost
all projects. | - Supporting Design for Manufacturing and Remote Flexibility
Vacuum casting is frequently utilized for prototyping, we
understand that many of the products . To facilitate their
refinement, we extend comprehensive design for manufacturing
assistance to our clients.
|
Vacuum Casting Materials
Acrylic-Like |
Acrylic-Like is a rigid and uncomplicated polyurethane plastic
designed to mimic acrylic (PMMA). It's used to craft components
that need some level of translucency, such as light panels, safety
screens, and automotive taillights.
|
ABS-Like |
ABS-Like is a versatile polyurethane plastic that imitates ABS
thermoplastic. Widely used, it's a reliable option suitable for
various parts.
|
Opaque Elastomer |
Opaque Elastomer is a polyurethane plastic designed to replicate
diverse rubber-like substances such as TPE, TPU, and silicone
rubber.
|
Materials
Select from a wide range of materials for your vacuum casting
projects at JYH.
- Rubber-like Polyurethanes
DESCRIPTION
Our versatile rubber-like polyurethanes, when paired with silicone
molds, create premium prototypes and small batches of end-use parts
with diverse material properties.
KEY CHARACTERISTICS
- Superb surface quality, similar to TPE, TPU, and silicone rubber.
- Great for shock absorption needs.
- Cost-effective for prototypes or small batches.
- Max part size: 1,900 x 900 x 750 mm (max volume: 10 liters).
DESCRIPTION
Our ABS-like polyurethanes offer diverse material properties for
creating high-quality prototypes or small production runs using
silicone molds.
KEY CHARACTERISTICS
- High-quality surface and intricate details, mimicking injection
molding.
- Materials are flame-retardant, food-safe, and UV-resistant.
- Affordable for prototypes or small production runs .
- Max part size: 1,900 x 900 x 750 mm (max volume: 10 liters).
DESCRIPTION
Our versatile PE/PP-like polyurethanes, when paired with silicone
molds, create top-notch prototypes and small batches of final
parts.
KEY CHARACTERISTICS
- Superb surface detail, injection-molded appearance, and lightweight
strength.
- Offers various cost-effective finishes.
- Ideal for prototyping and small production runs.
- Max part size: 1,900 x 900 x 750 mm (max volume: 10 liters).
Benefits Of Vacuum Casting
Vacuum casting offers efficient manufacturing of intricate shapes
with high precision, cost-effectiveness, and versatility:
- Easily create complex shapes with precision.
- Simultaneously produce multiple components for enhanced efficiency.
- Rapidly prototype using quality urethane for small batches.
- Diverse material properties with different polyurethanes.
- Economical manufacturing due to low polyurethane costs.
- Efficient silicone mold production compared to metal molds.
In the end
Vacuum casting offers cost-effective, efficient production compared
to traditional methods like injection molding and die casting. It
excels in small batch production and rapid prototyping due to its
low cost.
However, it's less efficient for mass production as it's limited to
casting a small number of products at once. Vacuum casting is
perfect for custom, low-volume manufacturing due to its
adaptability and versatility.
