Vacuum Casting Services
Get reliable vacuum casting services for high-quality prototypes and production parts at competitive prices. XinCheng offers highly detailed casting parts with consistent quality.
- ISO 9001:2015 certification
- Production grade quality
- Fast response
- Engineering support
What is Vacuum Casting?
Vacuum casting, also known as urethane casting, is indeed a manufacturing technique used to create high-quality, small-batch plastic or rubber parts. This process involves pouring liquid casting material, typically a two-part polyurethane resin, into a mold within a vacuum chamber.
The vacuum is applied to remove air bubbles and ensure proper material flow, resulting in parts with minimal defects and an excellent surface finish. In addition, material choice, part geometry, and master model usually determine the final effect of the cast parts.
Why Choose Vacuum Casting for Your Low-volume Production?
How Does Urethane Casting Work?
The vacuum casting process is straightforward and in three main steps. Trust our professional engineers and technicians to handle your project well.
Step 1: Making the Master Model
The master model is 3D solids of the CAD design, and its quality usually decides the casting urethane part’s quality. We use CNC machining to make a quality master pattern for tighter tolerance, optical clarity, and a glossy finish. Moreover, we can also use SLA for the master model when dealing with parts with complex designs and structures.
Step 2: Silicone Mold Making
We create our silicone casting molds from liquid silicone (RTV molds). The silicone rubber possesses excellent chemical stability, flexibility, and self-releasing properties that allow the imitation of fine details from the master and minimal shrinkage.
Depending on the part’s size, it takes 12-24 hours to complete the curing in an oven at 40 degrees Celsius. Once the silicone dries, we cut open the mold to extract the master model while we have an empty space: the original’s negative shape.
Step 3: Create Vacuum Casting Parts
We can easily create and replicate cast parts with exact mechanical features using our standard operational technique at XinCheng. We have expert urethane casting technicians that oversee the working framework, including mixing, degassing, stirring, preheating, casting, and demolding. You can be sure of a seamless operation and creation of impeccable copies of the master model.
Vacuum Casting Services at XinCheng
XinCheng offers you a perfect mix of high-tech facilities and extensive manufacturing capabilities to ensure you get superior-quality vacuum cast parts.
Vacuum Casting Materials
We use high-quality vacuum casting material at XinCheng. Although polyurethane is the only available material for vacuum casting. There are good ones and bad ones out in the market. At XinCheng, we always choose good materials made by good material supplier.
Polyurethane has many kinds. There are materials similar to PMMA, PC, ABS, Nylon, and more. XinCheng is here to help you choose the best one for your each project.
Surface Finish Standards for Vacuum Casted Parts
XinCheng offers a comprehensive list of secondary finishing operations to improve the mechanical and aesthetic appearance of your product. We will work with you to choose the suitable finishing option for your part’s application.
|A1, A2, A3
|We form this highly reflective finishing type by polishing the master model before mold creation. Its high-gloss finish provides the high transparency required for lenses, cosmetic components, and other cleanable surfaces.
|Although the semi-gloss grade is less reflective, it offers some shininess or gloss. However, you can achieve a smooth and cleanable surface between high-gloss and matte when you use gritty sandpaper
|Sand or Bead blasting the master pattern can give vacuum cast parts a satin-like finish. The C-grade surface finish is well-suited for handheld products and high-touch areas.
|XinCheng offers custom surface finishing services through other processes. So, you can request unique secondary finishes to have the best results.
Vacuum Casting Design Tips
We use a standard tolerance of ±0.15mm/100mm, while the highest precision attainable is ±0.05mm.
Minimum Wall Thickness
We use the minimum wall thickness of 0.5mm, while the best ranges are between 1.5mm-2.5mm to fill the mold appropriately.
Maximum Part Dimensions
The vacuum tool can hold a 2.0M x 1.2M x 1.0M mold configuration.
Lifetime of Silicone Mold
A typical silicone mold makes up to 20-25 copies per mold. However, one mold can only create 10-12 cast parts in regular quantities for high-quality requirements.
Depending on the mold’s volume and complexity, we can produce about 50 copies within 7-10 days.
The regular surface textures include colored, painted, textured, inserted, coated, clear polished, and over-molding.