Vacuum Casting
We offer a complete turnkey solution for creating master models and casting copies from your CAD designs. Not only do we make high quality molds, we also offer a full range of finishing services including painting, sanding, pad printing, and more. We'll help you create parts for showroom quality display models, engineering test samples, crowdfunding campaigns, and more.
Do you need to produce high quality plastic prototypes quickly? Polyurethane vacuum casting may be the ideal solution for you. wintech's vacuum casting services are known for producing showroom quality display models, engineering samples, crowdfunding prototypes, and more. Of course, all of your parts are professionally painted, printed and finished.
Polyurethane vacuum casting is a specialized technique for making high fidelity master mold copies using inexpensive silicone molds and castable resins. Copies made in this manner demonstrate the same quality as plastic injection molded parts, while requiring a fraction of the time and expense to produce.
Low mold cost
Molds can be made in a matter of days
Many types of polyurethane resins are available for casting, including overmolding
Casting copies are very accurate and have excellent surface texture
Molds are durable and can be made in 20 or more copies
Ideal for engineering models, prototypes, rapid prototypes, bridges for production
Product developers turn to vacuum casting when they need only a small number of production-quality plastic parts between 10 and 20 pieces, while avoiding the longer lead times and financial commitments of manufacturing plastic injection mold tools.
These parts are used for prototypes and display models, crowdfunding and trade show events, to test the fit and functionality of new designs, and as a bridge to larger production volumes. Vacuum casting can also be used for end-use parts in certain applications, as castable resins effectively mimic the properties of ABS, nylon, PP, acrylic and soft TPE rubber.
The vacuum castable materials we use at Wintech are two-part resins that we mix before pouring them into silicone molds. These resins are analogs of common plastic injection molding materials, and they have comparable appearance and properties.
We can replicate polypropylene, ABS, nylon, acrylic and soft elastomers of various hardnesses. We can also add glass fibers to increase the stiffness of ABS and nylon to provide additional design options.
The production of polyurethane vacuum cast parts is divided into three steps: making the master mold, making the mold and casting the parts.
Step 1. Mastering the pattern
Patterns are 3D solids of CAD designs. They are usually made by CNC machining or 3D plastic printing (e.g. SLA/SLS). You can provide your own patterns, or we can make them for you. Patterns need to be able to withstand heating up to 40°C.
Master patterns can be any physical entity of your design. They are usually made by CNC machining or some form of 3D printing (e.g. SLA). Note, however, that patterns made by 3D printing are not exactly the same as their CNC counterparts, as the circular cutting tools used in the post-process do not allow for very tight radius corners.
Step 2. Making the mold
The casting molds are made of liquid silicone. This silicone is poured around the master mold in the casting box and then cured in the oven for 16 hours. After drying, the mold is cut and the master is removed, leaving a cavity that is exactly the same shape as the original negative.
The pattern must first be carefully prepared, which means sanding and sealing the surface with primer. Once ready, it is placed in the casting box and liquid silicone is poured around it. Depending on the size of the part, it may take 12 to 24 hours to fully cure in the oven. Once dry, cut the mold open and remove the master, leaving a cavity that is exactly the same shape as the original negative.
Step 3. Casting Copies
Your casting resin of choice can now be poured into the cavity to create a highly accurate copy of the original. Overmolding can even be done with two or more materials. Silicone molds are typically suitable for making about 20 copies of a master pattern.
Vacuum Casting Tolerances
The finished size of a vacuum cast part depends on the accuracy of the master model, the geometry of the part, and the type of casting material used. A shrinkage of 0.15% is usually expected.
When it comes to vacuum casting, there are many manufacturers to choose from. Choosing the right tool is critical to getting exactly the results you expect. Here are a few reasons to choose Wintech for your vacuum casting needs.
Superior quality and speed
Quality should not come at the expense of speed, and vice versa. At Wintech, we combine our extensive experience with the industry's latest tools and technologies to deliver high-quality vacuum casting services in a short time frame, typically 7 to 14 days.
Finishing services to enhance your product
Vacuum casting isn't all we do. As your one-stop production shop, we also offer a wide range of complementary finishing services to help bring your products to life. Our finishing services include machining, media blasting, printing, painting, and more.
Smart quotes for every project
Your needs are unique - and you don't want to pay more than you need to. That's why our vacuum casting services never require a minimum order quantity or a minimum dollar value. We also use state-of-the-art AI quoting algorithms to provide fast, accurate quotes for virtually any project in 24 hours or less.
Manufacturing support and remote design flexibility
Since vacuum casting is often used for prototyping, we know that many of the products we work on have not yet reached their final design. To help them achieve their goals, we provide our customers with detailed designs for manufacturing support. (We can even create patterns for you.) We also provide detailed video documentation showing all production steps for customers who cannot visit us in person.
Industry Leading Material Verification and Testing Services
To ensure superior product quality from the start, we use only the highest quality resins from the best international brands.
What makes Wintech's vacuum casting services different?
Our vacuum casting services are known for their superior quality and speed. Our skilled technicians combine decades of experience with the latest technology to quickly produce superior prototypes and engineered models. We can also further enhance your parts with a range of finishing services, including machining, media blasting, printing, painting, and more.
Can Wintech offer design services, industrial design support or product development support as an extension of its vacuum casting services?
Yes. To complement our vacuum casting services, we offer extended services geared toward manufacturing design support. While we used to reserve this service only for approved orders, we now offer this service for all RFQs received. We also offer fixture assembly services to meet your needs.
What are the quality standards for Wintech vacuum casting services?
To ensure that the quality of all your finished parts is of the highest standard, our team adheres to a strict quality control process. This begins with the verification and testing of all materials. During production, we carefully control temperature, humidity and other processing conditions to maintain the highest degree of consistency in your parts.
How do I get a quote for Wintech vacuum casting services?
We make it easy to get a quick quote. Simply upload your CAD file and product details and we'll send you a free quote within 24 hours. Or less.
What are the limitations of vacuum casting?
The vacuum casting process has some limitations. Developers need to use good design practices to ensure that there are enough drafts available so that parts can be released. For the same reason, avoid undercuts, deep ribbing, tabs, and other features that can damage relatively soft silicone molds when they are opened.
What keeps the mold together in vacuum casting?
When our technicians cut the mold to remove the master pattern, they create a serrated pattern on the cutting line, like a key. This helps reseal the mold in the correct orientation for pouring resin. The mold simply needs to be taped and nailed down to avoid any leakage during the pouring process.
