Vacuum-cast polyurethane (PUR hard) Wide variety of materials with series-like properties
Vacuum casting is ideal for duplicating models. Starting from a master model, a silicone mold is created which is then used to duplicate parts made from polyurethane (PUR plastic). The desired surfaces for the finished part are for the most part already applied to the master model (structure according to VDI 3400, high gloss) and thus reproduced in the silicone mold. At 1zu1, we can therefore produce components that are indistinguishable from a later original injection-molded part.
Materials
Technical prototypes should be as identical as possible to the later series products in terms of strength values. Our vacuum casting optimally fulfills the requirements for components in terms of their performance properties and fatigue strength and can therefore be used both in the prototype phase and in series production. 1zu1 has various materials at its disposal to make your desired plastic part possible.
| 070* | 085** | 090.1 | 092 | 095GF | 100** | 122 | |
|---|---|---|---|---|---|---|---|
| Shore D hardness | 68 ± 2 | 72 ± 4 | 80 ± 1 | 82 | 85 | 80 ± 2 | 84 ± 2 |
| Density [g/cm3] | 1.08 | 1.15 | 1.2 | 1.20 ± 0.02 | 1.23 ± 0.02 | 1.14 ± 0.02 | 1.06 ± 0.02 |
| Flexural strength [MPa] | 30 | 80 | 105 | 105 | 150 | 80± 2 | 100 |
| Bending modulus of elasticity [MPa] | 500 | 1200 | 2100 | 2500 | 4500 | 2300 ± 100 | 2000 |
| Tensile strength [MPa] | 25 | 40 | 60 | 70 | 85 | 60 ± 2 | 65 |
| Notch impact strength [kJ/m2] | no break | >50 | 71 | 70 | 30 | 60 | 94 |
| Elongation at break [%] | 100 | 25 | 7.5 | 15 | 3 | 12-14 | 7 |
| Thermal stability [°C] | 55 | 78 | 78 | 85 | 85 | 85 | 85 |
| Shrinkage [mm/m] | 7 | 3 | 5 | 3 | 2 | 3 | 7 |
| Base color | dark gray | translucent | creme | whitish | light gray | black | transp./diffused light |
| colorable | black only | yes | yes | yes | yes (dark color tones) | black only | yes |
| Final curing at 23°C | 7 days | 5 days | 1 day | 3 days | 3 days | 3 days | 4 days |
*Material is not in stock and is only ordered on the basis of a specific request.
**Material can be mixed with fiberglass and is available based on a specific request.
Do you have high demands in terms of transparency, gloss level and light transmission? The cast resin 122 that we use enables the production of transparent molded parts such as displays, containers, light guides and lenses that are precisely tailored to your specific requirements. Its approximate characteristic values compared to the series materials polycarbonate (PC) and Plexiglass (PMMA) are shown clearly in the following table.
| 122 | PMMA | PC | |||
|---|---|---|---|---|---|
| Color | transparent | transparent | transparent | ||
| Translucency [%] | >90 | 92 | 88-90 | ||
| Refraction index | 1.50 | 1.49 | 1.58 | ||
| Density [g/cm3] | 1.06 ± 0.02 | 1.18 | 1.20 | ||
| Hardness [Shore D] | 84 ± 2 | 90 | 82-84 | ||
| Bending modulus of elasticity [MPa] | 2000 | 2800 | 2100 | ||
| TG [°C] | 90 | >80 | >100 | ||
| Impact strength (Charpy smooth) [KJ/m2] | 94 | >11 | no break |
The final touch
We are happy to cast the molded parts in colors according to RAL, Pantone, NCS or according to your sample. Individual color samples or color requests according to RAL, Pantone or NCS are also possible. In addition, we can finish the surfaces of your components with different paint finishes on request. (Lacquers for electromagnetic compatibility, electroplating lacquers in different colors, partial lacquers, lacquers to improve UV stability or resistance, etc.) Individual printing, laser marking and hot foil stamping are also available in-house.
Your advantages
- Short lead time for production of components: first deliveries possible after 5-15 days
- Duplication of models by vacuum casting with up to 1,000 parts
- High accuracy: components hardly distinguishable from the original injection molded part,
- Surfaces according to customer requirements: high gloss, fine structures, varnishing, printing
- Perfect coloring of the casting resins in accordance with RAL, Pantone, NCS or based on your sample
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!
