Complex Ergonomic Razor Handles Including Intricate Features and Over Mouldings “Parts can be produced in a wide array of materials to simulate most engineering plastics”.
View more projects like this
High Accuracy Vacuum Castings Used to Produce Valve Blocks The silicone tooling needed to produce the 30 sets of polyurethane castings was enhanced with high precision metal inserts to maintain the tight tolerances required in some of the bores.
View this project
High Accuracy Vacuum Castings used to Prototype Valve Systems The prototypes were put to use in engineering evaluation, fit and function tests and regulation approval.
View this project
50 Trophies Vac Cast for the Topping Out Ceremony These model “trophies” were as a thank you to all those that helped with the building of the iconic building. They were given out during the “Topping Out Ceremony”.
View this project
Evoque Shaped Swatches Vac Cast for the Prestigious Dealerships. CAD and additive layer manufacture (rapid prototyping) has enabled architects to rapidly produce scale models of even the most complicated of structures. Our SLA materials are ideal for depicting intricate designs with a range of possible surface finishes, including optically clear materials.
View this project
Market Research Sets Produced by Vacuum Casting The tooling process will completely emulate the surface finish of the master pattern, by using MNL’s highly experienced team of model-makers the full set of components went through a wide variety of finishes from satin, light spark through to a perfect high gloss.
View this project
Tactile Rubber Overmouldings 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.
View this project
40 trophies Produced by Vacuum Casting The 3D printed gloss models were used as a pattern for silicone tooling, then vacuum cast in polyurethane resin, subsequently metalized chrome and then dipped in gold tinted lacquer.
View this project
Get a Quote Now

Vacuum Casting

Vacuum casting is a method to replicate components, often used in the prototype phase of product development. Strong durable polyurethane (PU) resin components can be produced from silicone tools. In general; MNL produces silicone tools from 3D printed masters, which have been surface finished to replicate the desired production finish. There are many PU resins to choose from, they differ in their physical properties and are often chosen to closely simulate an engineering plastic or elastomer.

Vacuum Casting in more detail …

  • “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.

The Vacuum Casting Process

A short video of the vacuum casting process in action.

Typical applications are endless …

  • Extensive product testing achievable on multiple sets for parallel tests.
  • Quick turnaround, 20 sets available within approx 2 weeks.
  • Can be cheaper than 3D printing, the break-even point is approx 4-5 sets.
  • Vacuum cast components are frequently used as market research models as they are often impossible to tell the difference between them and the production items.
  • Production bridge – vacuum castings can be used to bridge the gap whilst sales are ramping up to full production..
  • Low Volume Production – PU resin components from either vacuum casting or RIM processes offer excellent strength and durability suitable for production of low volumes.

Examples of Projects involving Vacuum Casting

Explore many different projects where vacuum casing has played a part. Various projects from single components produced multiple times, through to fully finished exhibition quality assemblies.

Get In Touch With Us For A Vacuum Casting Quote