Vacuum-cast PUR special materials Standard-compliant when exposed to heat, fire, food and light
Vacuum casting with silicone molds – a topic that has occupied us at 1zu1 for over 25 years. Vacuum casting is basically suitable as an economical downstream process for reproducing samples in small batches because of the low tooling costs. If you need low-cost plastic prototypes with material properties similar to those of series production at short notice, vacuum casting in silicone molds (silicone molding) is a suitable process.
The master model for vacuum casting is usually produced using the stereolithography process. A master mold made of silicone is cast from this model. This is then filled with liquid polyurethane casting resin (PUR) in the vacuum chamber. The vacuum prevents sink marks and the formation of pores. After curing, the surface finishing takes place.
In addition to standard materials, our portfolio also offers the option of manufacturing components in special materials.
Available materials
The selection of the best possible alternative for your series material is based on your individual requirements. Our experts can draw on numerous series materials when preparing the quotation. When determining these series materials, we put a lot of effort into market analyses, information on further developments on the market and thorough tests to find the right materials to perfectly meet your requirements.
We have approved the following special materials for series requirements:
- Impact-resistant and bending-resistant polyurethane
- Flame-retardant and self-extinguishing polyurethane resin
- High-temperature materials up to 190° Celsius
- Diffuser/light-scattering material for improved translucency
| 096 | 098 | 200 | |
|---|---|---|---|
| Shore D hardness | 80 | 86 | 80 |
| Density [g/cm3] | 1.16 | 1.35 | 1.20 ± 0.02 |
| Flexural strength [MPa] | 65 | 133 | 80 |
| Bending modulus of elasticity [MPa] | 1500 | 3700 | 1850 |
| Tensile strength [MPa] | 60 | 55 | 60 ± 2 |
| Notch impact strength [kJ/m2] | 20 | 26 | 41 |
| Elongation at break [%] | 5 | 4 | 13 |
| Heat deflection temperature [°C] | 130 | 90 | 190 |
| Shrinkage [mm/m] | 2 | 2 | 6 |
| Base color | black/brown | cream-colored | light amber |
| colorable | black | black/brown | black/brown |
| Final curing at 23°C | 3 days | 3 days | 3 days |
Special features of the process
The following must be taken into account when manufacturing components with special materials: If we offer an output of 1,000 parts from a single silicone mold with standard materials, this is not normally possible when potting special materials. The guaranteed output when using a high-temperature-resistant material, for example, is 10 to 15 parts, depending on the geometry of your component. Your requirements for the component are decisive.
Our aim is to be able to fulfill as many of your requirements as possible with the selection of one material.
Your advantages
- Fast, cost-effective production of near-series models (no injection molding tool)
- Surfaces according to customer requirements: high gloss, fine structures, varnishing, printing
- Large material variety
- High accuracy
- Error detection before series
- Possible construction changes or design adaptations can be implemented
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 |
Surface finishes
Here at 1zu1 we can treat master models, duplicated parts and serial parts with special surface techniques according to customer requirements . We finish the prototypes and serial parts via EDM texturing, high gloss, special effects (metallic, silver, partial) or subsequent varnishing.
We can also accommodate individual color samples or color requests (RAL, NCS, Pantone). For this purpose, we offer a wide range of surface treatment processes in manual finishing, depending on the initial technology. Each process can be applied individually, in combination, partially or fully, according to RAL or NCS.
The possibility of individual printing, laser marking as well as hot foil stamping is also available at 1zu1 in-house. Put us to the test!
