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Vacuum casting or low volume production involves making a mold out of silicone rubber, usually based upon a master model created by CNC machining or one of our rapid prototyping services. Vacuum casting is a low-cost but reliable method for making a small number of high-quality prototypes based on a master model. This method is ideal for rapid prototyping used in engineering testing, proof-of-concept and display demos to name a few.

There is a low initial cost since it doesn’t require investment in tooling. Low-volume manufacturing up to 100K pcs may be a great way for you to avoid a large investment while still producing high-quality parts. If the tool steel doesn’t need to be so durable then it will be more economical for you to purchase and faster for us to heat treat and machine. And, if your tool wears out during production and you need to have another one made, we do that at no extra charge!

Molds can be ready in a few days once the master model has been created low-volume manufacturing is the ideal way for you to make enough volume to be sellable without creating an unsustainable burden of inventory. In addition, with optimized supply chains for low volumes, the lead times are short with parts ready to go in a matter of days or weeks – not months – so you’ll have a quicker route to market.

Many different molding polymers are available that can be pigmented to meet your color requirements. During production, you may find some aspect of the design that you want to modify. Low-volume manufacturing lets you make those changes without greatly impacting the total order.

Another benefit of low-volume manufacturing is that it provides a way for you to scale up to eventual full-scale production. That’s why it’s sometimes known as bridge production or bridge tooling. As volumes progressively increase, you have an opportunity to streamline best practices to achieve further cost savings while improving product quality.

1.Making The 3D Printed Master Model

Vacuum casting requires the use of a master model, from which copies are then made. We created the master by taking the client’s CAD data and 3D printing it using stereolithography (SLA).

2.Making The Vacuum Casting Mold

The vacuum casting mold is built around the master model. We will use it to make replicas of the original. Molds are made one-half at a time, each half cured in an oven at 70° C for 15 hours. It’s important at this time that our technicians carefully arrange the location of gates (for filling the mold cavity) and overflows (which let excess plastic and trapped air to escape).

3.Making The Vacuum Casted Copies

Step 1: Filling The Mold

Similar to plastic injection molding or pressure die casting, vacuum casting uses liquid resin poured into an empty cavity (the vacuum casting mold) to make prototype copies. The first step is to fill this mold, using simple filling spouts that our technician removes after the part is cured. Vents inside the mold help air to escape so that the cavity is filled completely. This air will later be evacuated out of the mold when it goes into the vacuum chamber.

Step 2: Unsealing The Prototype

We used pins and staples to hold the mold together while the resin was cured in the oven. We also used high-temperature tape to seal all sections of the mold tightly together. We were very careful when unsealing the mold, so as not to damage the soft silicone which can be used many times before it must be replaced.

Step 3: Opening The Mold

Many kinds of liquid resins can be used for vacuum castings, from very soft elastomers to hard engineering-grade plastics. For these copies, we tried polyurethane PX223 resin in black. This plastic is safe for food handling and will resist the high temperatures involved in making popcorn.

Step 4: Reusing The Mold for Up to 50 Prototypes

Notice the wavy cut pattern on the different mold sections. This ensured they were in the correct alignment for every casting, creating identical finished parts each time. Cutting the mold in three sections also helped to release the handle without damaging the mold. With care, a silicone mold can make 50 or more copies before it must be replaced. Of course the master model can be used to make an indefinite number of vacuum casting molds.

Step 5:Testing Clarity of Part Features

Vacuum casting provides excellent fidelity even to small part features. Notice the clarity of the “twist” logo on the handle, and how it was correctly reproduced in the casting.

Step 6:Testing Different Colors

Another advantage of vacuum casting is that it’s easy to test out different resins in various colors. The orange stirrer paddle was cast in a high-temperature polyurethane plastic. This is a great way to go through several design iterations to find the look and feel that’s just right, which is exactly what you want a prototype for.

GuangZhou GaoJie Model Design & Manufacturing Co.,LTD is professional in 3D printing, CNC machining and Vacuum casting fields, which has more than 15 years export experiences, a leading 3d printing enterprise in China, we have cooperated with many famous companies, look forward to becoming your trusted long-term Chinese supplier!

FAQ

Q: Are you trading company or factory?

A1: We are factory.

Q: How to get a quote?
A2: Please send your 3d drawing(STP, IGS, STL, OBJ, X-T...) to us, and tell us the material, surface treatment and quantity, then we will quote within 2 hours.

Q: Can I order one piece for testing?
A3: Yes.

Q: How long is your delivery time?
A4: 3 to 4 work days

Q: What is your terms of payment?
A: Payment<=1000USD, 100% in advance. Payment>1000USD, 50% T/T in advance ,balance before shipment.