Vacuum Casting Services
Your Partner in Volume Manufacturing
At Malcolm Nicholls Ltd (MNL), we deliver premium vacuum casting services, leveraging over 50 years of expertise to bridge the gap between prototyping and full-scale manufacturing. This process uses durable silicone tools crafted from expertly finished 3D-printed masters, ensuring precise, high-fidelity replication of components with a production-grade finish.
Our method is ideal for low-volume production and advanced prototyping, offering strong, durable polyurethane (PU) resin components that can closely simulate final production plastics or elastomers.
UK-based CNC Machining
Over 50 years of expertise
Custom parts delivered in days
Integrating Vacuum Casting for Optimal Results
Vacuum Casting is a central pillar of the modern Hybrid Manufacturing workflow, combining the best aspects of different technologies to optimise speed, cost, and quality.
The Core Hybrid Process – SLA to Silicone Tool to Cast Part
Our process begins with SLA 3D Printing (Stereolithography) to create a Master Model. This leverages the speed and high detail of 3D printing, while casting utilises the silicone tool’s ability to replicate the master up to 30-50 times depending on the materials being used in final-intent materials.
Benefit: You get the quick iteration speed of 3D printing combined with the material properties and surface finish of a cast part.
The Manufacturing Bridge
Vacuum Casting is the ultimate “bridge tooling” solution. Instead of investing immediately in expensive, high-volume metal injection moulds, you can use our rapid silicone tooling to:
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Conduct Market Testing: Provide pre-series parts for customer feedback or sales samples.
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De-Risk Investment: Fully validate material properties, function, and assembly before committing to high tooling costs.
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Scale Up: Use vacuum casting to meet initial demand while hard tools are being manufactured.
What We Offer
High-Fidelity Vacuum Casting:
We provide robust low-volume production using the Vacuum Casting process. By leveraging silicone moulds created from high-detail 3D-printed masters, we produce strong, durable polyurethane (PU) parts that accurately simulate engineering plastics (like ABS and Nylon) and elastomers. This is the cost-effective bridge between prototyping and injection moulding.
Advanced Integrated Functionality:
Our services include advanced finishing techniques like Overmoulding (casting a soft material onto a rigid core) and Insert Moulding (embedding metal threads). This allows us to deliver complex, assembly-ready components with superior mechanical performance and integrated features, just like final production parts.
Expert Hybrid Manufacturing and Finishing:
We utilise a Hybrid Manufacturing approach that strategically combines 3D printing (SLA, SLS, FDM), Vacuum Casting, and CNC Machining. Coupled with our in-house team of traditional model makers, we ensure every part from a raw print to a meticulously polished prototype is finished to perfection, meeting both functional and aesthetic requirements.
Unrivalled Speed and Design Flexibility:
Benefit from rapid tooling with silicone moulds created in days, not weeks, significantly reducing your time-to-market. Our vacuum casting process also supports exceptional design flexibility, allowing for the easy incorporation of complex geometries, undercuts, and fine surface textures that are difficult or impossible to achieve with standard CNC machining.
Bespoke Vacuum Casting & Rapid Prototyping Services
- “Parts can be produced in a wide array of materials to simulate most engineering plastics”
- Masters from any source or 3D printing technology 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¥
- 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.
Vacuum Casting Capabilities and Material Simulants
We can tailor materials to closely simulate virtually all engineering plastics and elastomers, ensuring your prototypes function and feel like the final product.
| Feature | Details | Material Simulants & Properties |
| Material Base | Polyurethane (PU) Resins and Silicone Rubbers | ABS, Polypropylene (PP), Nylon (PA), Polycarbonate (PC), Glass-filled Nylon. |
| Elastomers | Flexible Resins | Simulates TPE, Hytrel, and HDPE with Shore Hardness ranging from 30A up to 90A and various Shore D ratings. |
| Transparency | Clear Resins | Available for replicating clear components like PMMA or Polycarbonate. |
| Thermal/Specific | Specialised Resins | Temperature-specific and Flame-Retardant (FR) materials available. |
| Colouring | Custom RAL/Pantone matching | Parts can be mass-dyed for aesthetic prototypes and production-like consistency. |
| Dimensional Accuracy | 0.15 to 0.3 over 100 mm | High dimensional accuracy suitable for functional testing. |
| Surface Finish | Excellent, replicates the finish of the master model. | Suitable for market research models that are often indistinguishable from production items. |
The Malcolm Nicholls Advantage: Manufacturing Without Compromise
In today’s accelerated product development cycle, you shouldn’t have to choose between precision, material performance, and production speed.
At Malcolm Nicholls Ltd (MNL), we have strategically integrated three foundational manufacturing technologies CNC Machining, High-Temperature FDM, and Vacuum Casting to deliver the ultimate solution from initial prototype to low-volume production. We are experts in hybrid workflows, ensuring that whether your project demands sub-0.05mm tolerances in metal, aerospace-grade thermal stability in polymer, or cost-effective replication of small batches, MNL provides the perfect, unified manufacturing recipe. Our goal is to empower engineers and designers to innovate without being constrained by conventional manufacturing limits.
The Low-Volume Vacuum Casting Process
Integrated Functionality: Inserts and Overmoulding Solutions
We move beyond simple casting by incorporating advanced techniques that deliver final, assembly-ready components, providing an essential edge over basic prototyping services.
Threaded Inserts (Insert Moulding)
To hold tight tolerances and achieve robust connection points, we use Insert Moulding. Metal components, such as threaded inserts (brass or steel), are accurately placed within the mould before the resin is poured.
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Enhanced Strength: The polyurethane resin flows around the insert, creating a superior mechanical lock essential for parts that undergo repeated assembly or high stress.
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Precision: Ensures perfect alignment for mating components, eliminating the inaccuracy of post-tapping.
Overmoulding and Two-Shot Casting
Overmoulding is an intricate process where a secondary layer of material is cast onto an existing substrate. This delivers enhanced functionality, durability, and aesthetic appeal in a single component.
- Soft-Touch Grips: Casting a flexible elastomer (e.g. Shore A hardness resin) over a rigid plastic core to create ergonomic handles, seals, or dampening features for products like medical devices or consumer electronics.
- Integrated Seals: Creating a seamless, integrated seal or gasket, improving ingress protection against dust and water.
- Design Versatility: Allows for the seamless integration of different colours, material properties, and textures within a single component, accurately representing a final production part.
Securing Your 3D Printing Project with an NDA
We understand the sensitivity of your projects and operate with the utmost confidentiality. Strict adherence to non-disclosure agreements (NDAs) is ingrained in our company culture. We’re happy to work within your NDA framework and are prepared to sign mutual agreements to ensure your intellectual property remains safeguarded. Trust and transparency are cornerstones of our business, and we’re committed to partnering with you with complete peace of mind.
Examples of Projects involving Low Volume Vacuum Casting
Full-Service Capabilities
Our in-house team and trusted UK partners allow us to deliver at speed and scale. We combine traditional craftsmanship with cutting-edge production methods, including:
SLA
Stereolithography (SLA) Utilising two of the UK’s largest SLA 3D printers, and a suite of machines. We produce high-precision, large-format automotive components with exceptional surface finishes, ideal for both prototyping and end-use applications.
SLS
Employing SLS technology to create durable, high-tolerance parts suitable for functional testing and low-volume production, meeting the rigorous demands of the automotive industry
FDM
Delivering robust and cost-effective automotive prototypes and components, facilitating efficient design validation and testing processes
Large Format
Large format 3D printing service, utilising our large format SLA 3D printers with their impressive build platforms of 800 x 800 x 600mm.
Transparent
We can produce large transparent 3D printing without the need for sectioning and fabricating back together, by utilising our large format SLA 3D printers.
Carbon
Carbon has proven itself for its reliability in the toughest of environments, whether your looking to use it in low volume production or rapid prototyping Carbon 3D Printing is a great option.
Vacuum Casting
Our vacuum casting capabilities enable the production of high-quality, low-volume components that closely mimic final production parts, supporting seamless transitions from prototyping to manufacturing
CNC
With advanced 5-axis CNC machining, We manufacture precise metal and plastic automotive parts, ensuring high accuracy and superior surface finishes for both prototypes and production components.
RIM
Reaction Injection Moulding (RIM) utilising RIM to produce lightweight, impact-resistant automotive components, offering a cost-effective solution for low-volume production runs.
Vacuum Casting and Prototyping Services FAQ
What is Vacuum Casting?
Vacuum casting is a manufacturing process where silicone moulds are used to create high-quality prototypes and small production runs. During this process, materials are poured into a mould under vacuum removing air bubbles and ensuring high-quality output.
What are the advantages of Vacuum Casting?
- Faster turnaround times compared to traditional methods like injection moulding.
- Lower tooling costs ideal for prototypes, low-volume production runs, or complex geometries.
- Wide range of materials available with various properties for different applications.
- Excellent dimensional accuracy and smooth surface finish.
- Suitable for small and medium-sized parts with intricate details.
What are the limitations of Vacuum Casting?
- Limited production volume compared to injection moulding.
- Certain part geometries might not be suitable due to undercuts or draft angles.
- Material properties might not be as strong as some injection moulded parts.
What materials can be Vacuum Cast?
A variety of polyurethane (PU) resins can be used, offering properties like:
- High transparency
- Flexibility
- Durability
- Heat resistance
- Paintability
How long does the Vacuum Casting process take?
The turnaround time depends on the complexity of the part and the number of parts required. Malcolm Nicholls Ltd will work with you to provide an accurate estimate.
What kind of finishes can be achieved with Vacuum Casting?
Vacuum Cast parts typically have a smooth surface finish that can be left as-is, painted, or plated.
How much does Vacuum Casting cost?
Costs depend on the part size, complexity, material selection, and quantity. Malcolm Nicholls Ltd. will provide a competitive quote based on your specific requirements.
What file formats do you accept for Vacuum Casting?
We typically work with 3D CAD files in formats like STL, STP a full list can be found on this pop up here
Is Vacuum Casting suitable for my project?
Vacuum Casting is a versatile process ideal for prototypes, low-volume production runs, and parts requiring high detail and a smooth finish. Contact Malcolm Nicholls Ltd. to discuss your project and see if it’s a good fit.
Why choose MNL for your vacuum casting and prototyping?
At Malcolm Nicholls Ltd (MNL), we bring decades of experience in vacuum casting and rapid prototyping services. Our advanced technology, skilled team, and tailored solutions ensure that every project meets the highest standards of quality and precision. We specialise in delivering exceptional results for industries ranging from automotive to consumer goods.
Get in touch
Address
Waterloo Industrial Estate, Waterloo Cres, Bidford-on-Avon, B50 4JH
Call Us
01789 490382
Email Us
quotes@mnl.co.uk