Vacuum casting bridges the gap between a one-off prototype and full production tooling. It is the right process when you need multiple identical parts quickly and at a fraction of injection moulding cost. The process starts with a master pattern, typically a 3D printed or machined part finished to the required surface quality. A silicone mould is made from the master, and polyurethane resin is cast into it under vacuum to eliminate air bubbles and ensure accurate reproduction of detail. The result is a part that closely replicates the properties and appearance of injection-moulded plastic, with typical run lengths of ten to thirty parts per mould before the silicone degrades. Vacuum casting is particularly well suited to pre-production prototypes, functional test pieces, presentation samples and short runs where production tooling cannot be justified. Parts can be cast in a range of polyurethane resins with varying hardness, flexibility and surface finish, and coloured or finished to match the intended production part.
What We Cast Rigid housings and enclosures. Flexible over-moulded parts. Clear and translucent components. Rubberised grips and soft-touch surfaces. Structural components requiring mechanical properties closer to production plastic than standard 3D prints provide. We select the resin formulation based on the mechanical and aesthetic requirements of your specific part. The Master Pattern The quality of the cast is only as good as the master. We produce masters in-house using CNC machining or 3D printing, finished and primed to the required surface standard before moulding begins. If you already have a master or an existing part you want to replicate, we can assess it and advise whether it is suitable to mould directly or whether it needs reworking first.
