Skip to main content: Plastic vacuum casting – Top quality duplication with short lead times

Plastic vacuum casting
Top quality duplication with short lead times

Plastic vacuum casting – a common process for fast and inexpensive duplication of master models. With the help of these master models, a silicone mold is created which enables multiple identical parts to be cast in polyurethane casting resins. The use of a vacuum chamber prevents air inclusions in the mold and workpiece. 
Precision and accuracy are our top priorities. Our silicone molds are reinforced with high-end additives. This allows us to increase the accuracy of vacuum castings. The result: a reduction in delivery time. Wear and tear? A thing of the past.
Thus, instead of the usual 15 to 20 parts, we produce an almost “infinite” number of parts from our silicone molds. With the result that we can close the gap to series production. You benefit by paying the initial costs only once at 1zu1 when using standard PU resins.

Polyurethanes (as well as series materials) can of course be reinforced with various additives. The latter often produce different effects compared to their use in injection molding – for example, because the glass fibers are not “directed”.

  • Glass fibers/glass-fiber mats with a weight ratio of up to 20 percent are possible. Instead of higher strength, in most cases this results in increased hardness and dimensional stability and, in some cases, higher thermal stability. However, glass fibers reduce the elongation at break!
  • Carbon fiber/carbon fiber mats
  • Sand

 

Silicone
Flexible parts, such as hoses or seals made of silicone, can also be produced by 1zu1 in any color and in a Shore hardness of between 00 A and 65 A. Food-grade parts can also be produced in a Shore hardness of 00 A, 43 A and 65A. 

Rubber
Elastomer materials (PU rubber) are available in various degrees of hardness from  30-90 Shore A. Thermoplastic-like materials are available in degrees of hardness from 45-85 Shore D. Typical areas of application include housings, covers, gaskets, covers for vehicle apparatus construction, foundry models, model and prototype construction, mold tubes, hoses …

The term “food grade” refers to materials that are harmless to health due to their physical composition. They have no odor or taste effect on food. They give rise to new applications for prototypes and small-series production in the household appliance industry.

We have special expertise when it comes to prototypes made from food-grade plastics and silicones. The use of these basic materials, which are approved by the Food and Drug Administration (FDA), makes it easier to obtain FDA approval for the respective part.

We can hand over the necessary documentation for FDA approval to our customers, thereby enabling them to submit the respective FDA application. In this context, the term “food grade” refers to materials which, due to their physical composition, are harmless to health and impart no odor or taste to the food. They give rise to new applications for prototypes and small-series production in the household appliance industry.

For example, we tested the use of a transparent polyurethane material for vacuum casting on behalf of a well-known coffee machine manufacturer. Using food-grade dyes, plastic parts can be produced in virtually any desired color and adapted to meet the strict approval requirements of the American Food and Drug Administration.

Extensive advice
for optimal solutions

Experience shows: Projects in which 1zu1 comes on board as a sparring partner at an early stage can lead to novel solutions, lower lifetime costs and a shortened time-to-market. Because we advise comprehensively, independently of technology and with the goal of finding the optimal solution for your challenge.


Your advantages

  • Exclusive at 1zu1: 1 mold – 1,000 pieces (using standard PU resin) - one-off initial costs
  • Diverse material properties: production of hard, soft, transparent, clear, colored and rubbery parts possible
  • Various surface finishes possible -structure, high gloss, spray putty,…..
  • Additives such as glass fibers or others can be incorporated: higher strengths 
  • Technical inspection of the components
  • Design review
  • Construction and assembly options
  • Function test
  • Time: Due to the internal model making (STL/SLA), models and molds are available in a few days: first cast parts in a few days, series of 50 parts or more are feasible from 2-3 weeks (depending on customer requirements)

Advice tailored to your needs

At 1zu1, we help you find the perfect solution by combining the best technology with a wide range of materials. And this is implemented in the shortest possible time and with the highest technical precision.

Challenge us. What can I do for your project?

Stefan Rädler

1zu1sales
business developer additive manufacturing
T +43 5572 33 333-842
stefan.raedler@1zu1.eu

» For perfectly implemented ideas, I propose new technological paths with my customers.«

In motocross and enduro, Stefan Rädler is on difficult paths.

Stefan Rädler

1zu1sales
business developer additive manufacturing
T +43 5572 33 333-842
stefan.raedler@1zu1.eu

» For perfectly implemented ideas, I propose new technological paths with my customers.«

In motocross and enduro, Stefan Rädler is on difficult paths.

Klaus Pichler

1zu1sales
business developer
T +43 5572 33 333-838
klaus.pichler@1zu1.eu

»As a cyclist, I know that excellent technology is the key to speed – and therefore to success..«

Klaus Pichler spends his free time in the saddle – he and his road bike conquer Austria’s mountains with endurance and the right pedal stroke.

Sebastian Mathies

1zu1sales
business developer
T +43 5572 33 333-834
sebastian.mathies@1zu1.eu

»1zu1prototyping, that's like fast food on the level of top gastronomy. And if necessary, with a lot of portions.«

Sebastian Mathies knows that the eye also eats. That's why he chooses the right ingredients, the right technology and the necessary finishing steps. The result: prototypes to your taste.


Interesting facts about vacuum casting

Vacuum casting is a versatile and precise manufacturing technology that is primarily used in prototype and small series production. This process can be used to produce detailed, high-quality plastic components quickly and cost-effectively. Here you can find out everything you need to know about the process, its advantages and possible applications.

Vacuum casting offers numerous advantages over conventional injection molding. It is particularly cost-efficient for small series and prototypes, as tool production is less complex. The flexibility in the choice of material and design enables rapid adaptation to specific requirements. The precise vacuum process also allows complex geometries and fine details to be produced with high dimensional accuracy. The shorter production times make vacuum casting ideal for projects with tight schedules. The risk of material inclusions or surface defects is also minimized by the controlled vacuum atmosphere. This process is particularly suitable for development phases, as it offers high quality with comparatively low investment.

The vacuum casting process is characterized by its versatility and precision. It is often used for the production of prototypes and small series, as it is cost-effective and efficient. The basis is a silicone mold, which is created using a 3D-printed or CNC-milled model. Liquid polyurethane resins or other materials are poured into the mold under vacuum conditions. The vacuum prevents the formation of air pockets and ensures a smooth, detailed surface.

Another advantage is the large variety of materials, which makes it possible to realize properties such as strength, flexibility or temperature resistance precisely according to customer requirements. The simple mold production process also allows complex geometries and intricate structures to be produced efficiently.

Polyurethane is the collective chemical term for elastic to hard plastics produced from polyalcohols and polyisocyanates. The curing reaction is a polyaddition. Polyurethanes have many uses, e.g. for the production of household sponges, adhesives, paints and floor coatings. Synthetic textile fibers such as polyurethane are also used in the fashion sector.

1zu1 offers a wide range of Shore hardnesses to meet different material property requirements. In the field of vacuum casting, customers can choose from a wide range from Shore A (softer materials) to Shore D (harder materials).

The available Shore hardnesses include:

  • Shore A: From very soft materials (Shore A 10) to medium hard rubber (Shore A 85).
  • Shore D: For harder plastics, from Shore D 70 to Shore D 85.

This selection makes it possible to match materials precisely to the desired properties such as flexibility, strength or resilience. 1zu1 offers individual advice to determine the right Shore hardness for your project.

Classification of Shore hardness according to Albert F. Shore:

Shore A Shore D
10 -
20 -
30 -
40 5
50 15
60 25
70 35
80 40
90 55
95 65
100 75

Elastomer materials (PU rubber) are available in various degrees of hardness from  30-90 Shore A. Thermoplastic-like materials are available in degrees of hardness from 45-85 Shore D.

Shore A 30 40 50 60 70 80 90 95        
Shore D             45 55 60 65 70 80

Systems

At 1zu1 there are seven UGM - 400 systems, three UGM - 500 systems, one UGM - 700 system, two UGM - 850systems and one UGM - 1300 system in operation. All vacuum-casting systems work fully automatically, including automatic mixing and air blast for bubble-free casting and consistent quality, and have the following technical specifications:

Vacuum casting machine Vacuum pump capacity V Max. absolute ultimate pressure P Internal chamber dimensions Max. theoretical mold size Max. casting quantity
UGM 400 25 m³/h < 0.8 hPa 785 x 400 x 475 mm 530 x 400 x 475 mm 400 ml
UGM 500 40 m³/h < 0.5 hPa 800 x 500 x 635 mm 500 x 500 x 635 mm 600 ml
UGM 700 100 m³/h < 0.5 hPa 1120 x 600 x 950 mm 900 x 700 x 950 mm 3000 ml
UGM 850 200 m³/h < 0.5 hPa 1500 x 850 x 1585 mm 1000 x 850 x 1585 mm 2 x 5000 ml
UGM 1300 600 m³/h < 0.5 hPa 1700 x 1300 x 1290 mm 1200 x 1300 x 1290 mm 25 000 ml
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