Bridge the Gap From Prototype to Production – Global delivery in 10 days or less
Vacuum Casting Services
We offer metal & urethane vacuum casting. All processes run in sealed vacuum to eliminate air impurities. One-stop service: molds, casting, finishing, testing & delivery.
- 100+ Prototype Molding
- Million+ Production Molding
- Over 100 thermoplastics
How Does Urethane Casting Work?
he urethane casting process involves three key stages: master pattern creation, mold preparation, and casting.
Stage 1. Master Pattern Development
Urethane casting precision and finish depend directly on master model quality. Choose CNC for tight tolerance, glossy and clear parts; SLA 3D print for complex intricate shapes. We apply textures and satin finishes to match final look. Silicone molds replicate all details perfectly, saving extra post-processing work.
Stage 2. Silicone Mold Production
Durable high-performance RTV silicone molds feature low shrinkage and high detail replication. Mold making includes:
- Fix master model in box, set gates & vents for smooth resin flow.
- Add parting tape for easy mold split after curing.
- Vacuum pour silicone, cure 8-16hrs at 40°C for stable molds
Stage 3. Urethane Casting Process
We follow strict quality guidelines to guarantee consistent, high-performance urethane parts. The process involves:
- Preheat molds 60-70°C for fluent resin flow.
- Vacuum blend PU resin at 40°C briefly to avoid bubbles.
- Oven cure resin 1-6 hours as needed.
Focus on high-density, high-precision and high-purity castings
What is vacuum casting?
Vacuum casting is a precision casting technology that realizes metal smelting, pouring and solidification under vacuum or negative pressure. Its core advantages lie in air isolation, elimination of oxidation and porosity, as well as improved mold filling capacity and material density.
1：Vacuum castingis a high-precision process.We make silicone molds from 3D printed masters, then inject PU resin in vacuum.Vacuum eliminates bubbles for solid, flawless finished parts.It matches injection molding strength and surface finish with faster lead times and lower costs, perfect for prototypes and low-volume durable parts.
2：Zorapid vacuum casting ensures low ±0.1% shrinkage and high precision for parts up to 25 inches. It fits complex shapes and works with clear, flexible, heat-resistant PU materials. We embed metal threads & sensors, plus offer UV coating and textured finishing to meet all your needs.
3：Zorapid vacuum casting eases prototype to mid-volume production, cutting high injection mold costs and long lead times. Fast delivery plus strict quality control deliver affordable production-grade parts for automotive, consumer electronics and more.
Application Guide for Urethane Casting
Typical Accuracy
Standard tolerance: ±0.15 mm per 100 mm
High-precision control: ±0.05 mm for tolerance-critical components
ilicone Mold Lifespan
Standard silicone molds: 15–20 quality parts
Complex/clear urethane parts: 10–12 parts per mold
Standard Lead Time
Fast turnaround: 50 parts delivered in 7–10 daysLead time varies with part complexity and batch volume.
Surface Finishes & Features
Full range of finishes: color matching, surface textures, gloss or matte coating, insert molding, overmolding, and optically clear polishing.
Maximum Part Dimensions
Maximum mold dimensions: 1.8m × 1.0m × 0.8m. Perfect for large‑format prototypes and high‑performance functional parts.
Minimum Wall Thickness
Recommended wall thickness: 1.5mm–2.5mm. Minimum achievable thickness: 0.6mm for thin and detailed features.
Why Vacuum Casting is Better
Superior Surface Finishes
Our urethane casting achieves smooth, high-quality surfaces with sharp details without extensive finishing. This saves time and cost compared to machining or 3D printing for presentation and functional parts.
Cost-Effective Silicone Molds
Urethane casting employs affordable silicone molds instead of costly metal tooling, enabling fast, accurate production of functional prototypes and low-volume end-use parts with minimal upfront cost.
Rapid Turnaround Times
Achieve fast lead times of 10–15 days for up to 50 functional urethane parts, enabling faster validation and shorter time-to-market for your prototypes and low-volume production runs.
Diverse Material Options
Benefit from a broad portfolio of polyurethane materials, such as flexible, rigid, impact-resistant, and optically clear options, formulated to achieve realistic functional and mechanical properties.
High Precision and Detail Replication
Achieve production-level precision for complex geometries and ultra-fine details. Our casting process ensures parts adhere to tight tolerances and perform reliably in functional testing and real-world applications.
Typical Uses for Vacuum Casting
Small-batch / Short-run manufacturing
Vacuum casting is a reliable small-batch solution for 10–500 high-precision prototypes and end-use parts. It avoids high costs and long lead times of injection molding, delivering production-grade parts faster. Advanced polyurethane resins match ABS, PP, rubber and engineering plastics, enabling functional testing with low upfront investment.
Aesthetic Models / Color & Texture Prototyping
Vacuum casting enables you to build accurate visual prototypes with custom colors, textures, and surface finishes. Quickly produce 10–15 parts to verify different design versions like matte, gloss, and metallic effects for design review and customer approval. It removes uncertainty in product appearance and guarantees consistency with brand standards before full production.
Engineering Verification / Functional Testing
Vacuum casting is ideal for functional validation and cost-effective design optimization.
Produced prototypes exhibit excellent resistance to mechanical stress, heat, and simulated environments, supporting critical testing for certifications.
Low-cost soft tooling enables rapid revisions, greatly reducing development risks prior to mass production.
Marketing & Display Models
Photorealistic display models are ideal for trade shows, user experience testing, and online marketing.
Vacuum cast parts deliver production-level aesthetics and performance, supporting client interactions and pre-market evaluation.
Quick design iterations ensure your display models stay aligned with the latest product development for brochures, websites, and exhibitions.
FAQ
Why should I choose vacuum casting over other methods?
How many times can you use the silicone mold?
What’s the minimum order? Can I just get 1 piece?
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