Vacuum Casting
In development projects, there is often a need to perform functional tests at an early stage with materials that simulate the final construction plastic. By creating molds in silicone, details can be quickly cast in polyurethane plastic, PUR, with such properties.
Silicone tools
There are primarily a few advantageous characteristics that stand out when it comes to silicone tools. They can be manufactured very quickly, and complex undercuts and uneven material thicknesses can also be accommodated.
Max Dimensions Tool: 1300x500x500mm // 750x750x450mm
(Note: Verify with 1zu1)
General: The tools are typically cast from a 3D-printed master. The master can also be produced using other methods.
Surface: Everything from a raw surface to polished or textured. Your requirements determine. Logos and texts can also be added.
Viability: Usually up to 25 castings, but we also have special silicones where we can cast up to 1000 components.
PUR casting
PUR (Polyurethane) is a thermosetting plastic with properties that mimic several different thermoplastics, including TPE, PP, ABS, PC, and PA. We can also control hardness and color according to your preferences. It is also possible to add fiberglass for increased rigidity or additives to achieve light diffusion in transparent components. We can cast electronics, cables, plates, and threaded inserts. We can also cast so-called 2K components. The cast components are then finished to the desired level. The components are cast in a silicone tool.
Maximum dimensions for PUR components: 1250x450x400mm // 700x700x400mm in one piece. Shot weight up to 3.5 kg.
(Note: Verify with 1zu1)
General: Mimics thermoplastics ranging from soft elastomers to glass-reinforced rigid materials. Also available as flame-retardant material in UL94-V0.
Surface: Controlled by the finish on the master model, but subsequent polishing, painting, and printing can be added.
Viability: According to your preferences, considering the base color of the chosen material.
Silicone cast
When casting details in silicone, tools made of silicone, milled from block materials, or 3D-printed are used. Since the viscosity of silicone differs from polyurethane, we use a combination of vacuum and low pressure to fill the mold.
Maximum dimensions: 300x300x300mm. Shot weight up to 800 grams.
Features: Silicone ranging in hardness from Shore 0A to 65A is available. There are also FDA-approved silicones that are "food grade".
Finish: Controlled by the finish on the tool.
Colour: According to your preferences, considering the base color of the chosen material.
FAQs
Vacuum casting is a suitable choice when you need to:
- Develop functional prototypes that mimic the properties of the final component
- Produce low volumes and aim to reduce tooling costs
- Need a short lead time for time-critical projects
- Experiment with material properties like flexibility, rigidity, heat resistance, and/or color
Consider factors such as cost, production volume and lead time requirements when deciding on the use of vacuum casting.
- Casts under vacuum, resulting in pore-free components
- Offers various surface finishes and colors
- Speed
- Also possible to cast parts in silicone, perform 2K casting, or encapsulate other components
The process involves casting a silicone mold based on a master model. The silicone mold is used to cast multiple parts in polyurethane (PUR). We can mimic various surface finishes and different material properties. Therefore, we can produce components that are nearly impossible to distinguish from traditionally injection-molded components.
Do you require any post-processing before delivery? This can include adding graphic printing, installing threaded inserts, and assembling complete components.
We can also paint the cast components according to your preferences. This can be with RAL, NCS, Pantone, or metallic colors. We can also EMC-coat the components.
- • Components are cast in PUR, simulating various thermoplastics, from rubber qualities with Shore 30-95A to glass-reinforced rigid materials
- Flame-retardant material V0 is also available
- The components can be colored in your desired shade, specifying, for example, NCS or RAL colors
- For increased torsional rigidity, fiberglass can be added
- Approximately 20-25 components can be cast in each mold cavity. Multiple mold cavities can be created for larger quantities. We also have special silicone for up to 1000 castings
- It is fully possible to cast in metal components or electronics
- No consideration needs to be taken for draft angles
- If you want stronger threads, we can cast-in or retrofit threaded inserts
