Vacuum Casting

“Parts can be produced in a wide array of materials to simulate most engineering plastics”

Masters from any source are used to produce silicon tools from which castings can be produced in a wide array of materials to simulate most engineering plastics.

We can produce Polyurethane (PU) castings in the following material simulants or properties: ABS, Polypropylene, Nylon, Glass-filled Nylon, Polycarbonate, TPE, Hytrel, HDPE, etc. Temperature specific materials, flexible materials with A Shore ratings as low as 30A up to 90A and D Shore ratings also.

In general MNL’s silicone tools are guaranteed to produce a minimum of 30 castings per cavity¥, there are exceptions to this e.g. elastomeric resins yield many more components and up to 50 castings per cavity are possible. Tools are available in multi-cavity versions in order to produce larger quantities quicker and more economically. Metal inserts are used to hold tight tolerances in bores and critical areas etc. In these scenarios we have been known to hold tolerances as tight as ±0.05mm.  (¥ This figure depends upon the resin chosen, some resins degrade the tool more – Tool life will be quoted at time of quotation)

 

 

Typical applications are endless; however here are just a few areas where we have produced PU parts where our competitors couldn’t:   Medical remote control handset with gloss finish, functioning multi-coloured flexible keypad and integrated built-in over-moulded seal, to provide a pressure-tested watertight seal.

Under-the-bonnet common rail fuel system component, combining high accuracy stepped bores (±0.05mm) with a high temp requirement of 120°C and a resistance to fuel, oil etc. The components excelled in the tests coping with 14 Bar of pressure.

Chrome effect parts. Parts to represent chrome plating are achieved using a mirror gloss finish master and high temp PU castings which are subsequently vacuum-metalized

A Short Video to see the Vacuum Casting Process in Action

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