High-quality master pattern
Create or qualify the master geometry and surface because every silicone mold and cast copy carries its details forward.
SMALL-BATCH POLYURETHANE PARTS
Vacuum Casting Services for Prototype and Pre-Production Parts
Produce small batches of polyurethane parts from a qualified master and silicone mold—without investing in production injection-mold tooling.
Small batchPROTOTYPE QUANTITIES
PolyurethaneRIGID + FLEXIBLE OPTIONS
Color & textureAPPEARANCE CONTROL
No hard toolLOWER UPFRONT COMMITMENT
VACUUM CASTING CAPABILITIES
Production-like parts before injection-mold tooling.
Vacuum casting is suited to appearance models, assembly trials, customer samples, functional evaluation and low-volume pre-production when molded behavior matters but hard tooling is not yet justified.
Flexible mold production
Plan parting, gating, venting and extraction around the geometry, resin behavior and expected number of usable casts.
Rigid and flexible urethanes
Select material behavior, color, transparency, texture and finishing around the intended prototype or validation task.
PROJECT WORKFLOW
From approved master to inspected small batch.
The master, silicone mold, resin and finishing route are reviewed together so the delivered parts answer the intended design or market question.
RFQ review
Confirm CAD, drawing, quantity, appearance, material behavior and critical dimensions.
Master preparation
Produce and finish the reference master to the agreed geometry and surface standard.
Silicone molding
Build the flexible tool with planned split lines, gates and vents.
Vacuum casting
Mix, degas, cast and cure the selected polyurethane under the controlled route.
Finish & inspect
Trim, finish, assemble when required and verify agreed characteristics.
BEST-FIT APPLICATIONS
Use vacuum casting when appearance and molded behavior matter.
The process fills the gap between one-off additive prototypes and production injection molding. It is not a substitute for production tooling when long mold life, production resin data or high repeat volume is required.
- Appearance prototypes for customer or stakeholder review
- Assembly and fit-check batches using molded-form parts
- Multiple color or texture variants for evaluation
- Flexible covers, grips, seals and overmold-like prototypes
MATERIAL BEHAVIOR
Specify the performance the prototype must represent.
Polyurethane systems can approximate different rigid, flexible, clear or temperature-resistant behaviors, but they are not automatically identical to production thermoplastics.
Structural prototype parts
Used for housings, covers, bezels and components requiring a production-like molded appearance and controlled stiffness.
Soft-touch and elastomeric parts
Suitable for grips, seals, boots, pads and protective elements where flexibility or tactile response must be evaluated.
Appearance evaluation
Color matching, tinting, polishing, painting and texture can be reviewed for visual models and presentation parts.
DESIGN & QUALITY
Plan around shrinkage, mold life and the master surface.
Final accuracy and appearance depend on the master, silicone mold, resin shrinkage, extraction, curing and finishing. Define the dimensions that control fit separately from general appearance expectations.
- Identify critical assembly and fit dimensions
- Define cosmetic surfaces, color, gloss and texture
- Confirm inserts, bonding or assembly requirements
- Agree inspection scope and acceptable batch variation
Frequently asked questions.
How is vacuum casting different from injection molding?
Vacuum casting uses flexible silicone molds and polyurethane materials for small batches. Injection molding uses hard tooling and production thermoplastics for higher-volume, repeat manufacturing.
How many parts can one silicone mold produce?
Mold life depends on geometry, undercuts, resin, surface requirements and extraction stress. The expected usable quantity is reviewed for each project rather than treated as a fixed number.
What files should I provide?
Send a 3D model, drawing or critical dimensions, target quantity, required material behavior, color, texture, cosmetic zones and the purpose of the build.
START A VACUUM CASTING PROJECT
Get a vacuum casting quote ↗Tell us what the prototype needs to prove.
Engineering will review the master route, polyurethane behavior, silicone mold plan, finish, quantity and inspection requirements before quotation.