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.

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
Area of Responsibility: Gemany
T +43 (0)5572 33333-842
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
Area of Responsibility: Gemany
T +43 (0)5572 33333-842
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

1zu1vertrieb
Area of Responsibility: Austria
T +43 (0)5572 33333-838
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 Fink

1zu1Sales
Area of Responsibility: Switzerland, Liechtenstein, Vorarlberg
T +43 (0)5572 33333-839
sebastian.fink@1zu1.eu

“When it comes to perfect prototyping, it’s safe to say that we are the right address.”

Sebastian Fink is a trained instrument maker and plays the bass clarinet – his personal anti-stress program.

The vacuum process enables fast, efficient and cost-effective production of desired structural and molded parts. In addition, two different materials (hard and soft) can be combined during production. Inserts (magnets, threads, inserts, etc.) can also be integrated into the component.

The production process takes place in a vacuum or under negative pressure. What is the effect of this vacuum? On the one hand, it ensures bubble-free processing of the material. On the other hand, flow resistance within the mold caused by air pockets is avoided. This means that at 1zu1, we can achieve homogeneous, pore-free material properties.

  • From master model to casting mold:
    • Casting in vacuum
    • For simple components directly via a casting mold in 3D printing or milling technology: For series application 1zu1 recommends 100 to 200 pieces.
  • 3D printing of silicones: 
    • Discharging the material via nozzles or injecting a catalyst into a silicone bath 
    • Cantilevered components are possible 
    • Layered structure visible 
  • Vacuum casting materials: use of original silicone, including food-grade silicone

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.

SHORE hardness, named after Albert Ferdinand Shore, is an indicator used primarily for elastomers and rubber-elastic polymers. It is directly related to the penetration depth and is thus a measure of the material hardness.

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 A3040506070809095    
Shore D      455560657080

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 machineVacuum pump capacity VMax. absolute ultimate pressure PInternal chamber dimensionsMax. theoretical mold sizeMax. casting quantity
UGM 40025 m³/h< 0.8 hPa785 x 400 x 475 mm530 x 400 x 475 mm400 ml
UGM 50040 m³/h< 0.5 hPa800 x 500 x 635 mm500 x 500 x 635 mm600 ml
UGM 700100 m³/h< 0.5 hPa1120 x 600 x 950 mm900 x 700 x 950 mm3000 ml
UGM 850200 m³/h< 0.5 hPa1500 x 850 x 1585 mm1000 x 850 x 1585 mm2 x 5000 ml
UGM 1300600 m³/h< 0.5 hPa1700 x 1300 x 1290 mm1200 x 1300 x 1290 mm25 000 ml

Read more

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[Translate to English:] Automatische Zahnbürste aus dem Vakuumguss

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[Translate to English:] Automatische Zahnbürste
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