AIXI provides a comprehensive turnkey solution for creating master patterns and cast copies from your CAD designs. We specialize in producing high-quality molds and offer a complete range of finishing services, including painting, sanding, pad printing, and more. Whether you need parts for showroom-quality display models, engineering test samples, or crowdfunding campaigns, we’ve got you covered.
If you require production-quality plastic prototypes quickly, polyurethane vacuum casting could be the perfect choice. AIXI’s vacuum casting service is well-known for delivering showroom-quality display models, engineering samples, crowdfunding prototypes, and more. Plus, all of your parts are professionally finished with expert painting, printing, and machining.
Vacuum casting is a precise technique used to create high-quality replicas of master patterns by using cost-effective silicone molds and pourable casting resins. Parts made through this method offer the same quality as injection-molded plastic parts, but with significantly lower production time and cost.
Inquire About Vacuum Casting
Feel free to reach out to us for more details on vacuum casting. Our customer support team will get in touch with you directly to address any questions or concerns you may have.
Product developers often choose vacuum casting when they need a small batch of high-quality plastic parts, typically between 10 to 20 pieces, without the long wait times and high costs associated with creating plastic injection molds.
These parts are ideal for prototypes, display models, crowdfunding campaigns, and trade show samples. They are also used to test the fit and functionality of new designs and can serve as a stepping stone to larger production volumes. In certain cases, vacuum casting is also suitable for producing end-use parts, as the casting resins closely replicate the properties of materials like ABS, Nylon, PP, acrylic, and soft TPE rubber.
At AIXI, we use two-part resins for vacuum casting, mixing them right before pouring into the silicone molds. These resins are designed to mimic the characteristics of commonly used plastic injection molding materials, offering similar appearance and performance.
We can replicate materials like polypropylene, ABS, nylon, acrylic, and various grades of soft elastomers. Additionally, we can incorporate glass fibers to enhance the stiffness of ABS and nylon, providing more design possibilities.
Why Choose Us?
With many manufacturers offering vacuum casting, selecting the right one is crucial to achieving the desired results. Here are a few reasons why AIXI is the ideal choice for your vacuum casting needs.
At AIXI, we believe that quality and speed should go hand in hand. By leveraging our extensive experience and the latest tools and technologies, we provide top-notch vacuum casting services with quick turnaround times, typically between 7 to 14 days.
Vacuum casting is just one of the many services we offer. As your full-service production partner, we provide an array of finishing options to bring your product to life. Our finishing services include machining, media blasting, printing, painting, and much more.
We understand that each project is unique, and you don’t want to pay for unnecessary extras. That’s why we don’t have a minimum order quantity or minimum dollar amount for our vacuum casting services. Additionally, we use advanced AI-driven quoting algorithms to provide quick and precise quotes, usually within 24 hours, for almost all projects.
Since vacuum casting is frequently used for prototypes, we understand that many products are still in development. To assist in refining these designs, we offer comprehensive design for manufacturing support to our clients (we can even create your patterns for you). For clients unable to visit us in person, we also provide detailed video files that walk through all production steps.
To guarantee outstanding product quality from the start, we exclusively use premium resins sourced from the leading international brands.
Patterns are 3D replicas of your CAD designs, typically created using CNC machining or 3D plastic printing technologies like SLA/SLS. You can either provide your own patterns or have us create them for you. The patterns must be durable enough to withstand temperatures up to 40°C.
A master pattern refers to any physical representation of your design. These are commonly made through CNC machining or various forms of 3D printing, such as SLA. However, keep in mind that a pattern created via 3D printing may differ from one made with CNC machining, as the latter uses round cutting tools that can’t produce very tight radius corners.
Casting molds are created using liquid silicone. The silicone is poured around the master pattern placed inside a casting box, then cured in an oven for 16 hours. After curing, the mold is cut open, and the master pattern is removed, leaving a cavity that exactly replicates the original shape.
To begin, the pattern must be carefully prepared by sanding and sealing its surface with primer. Once it’s ready, it’s positioned in a casting box, and liquid silicone is poured around it. Depending on the size of the part, curing in the oven can take anywhere from 12 to 24 hours. After the mold is fully cured, it’s opened, and the master pattern is removed, leaving behind a cavity that mirrors the original design perfectly.
Now, you can pour your selected casting resins into the empty cavity to produce a precise replica of the original. It’s also possible to perform overmolding with two or more materials. Typically, silicone molds can be used to make around 20 copies of the master pattern.
The final dimensions of vacuum cast parts are influenced by the precision of the master pattern, the design of the part, and the type of casting material used. Typically, a shrinkage rate of around 0.15% is expected.
The latest and greatest post and projects from AIXI
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Tiny, lightweight, and advanced sensors are housed in discreet cases, made with the assistance of AIXI’s vacuum casting service.
Frequently Asked Questions
Interested in learning more?
Vacuum casting is a process where liquid silicone molds are created around a master pattern, and then casting resins are poured into the mold to replicate the original design. It’s ideal for creating high-quality prototypes or small production runs.
We offer a range of polyurethane resins, which can mimic the properties of materials like ABS, Nylon, polypropylene, acrylic, and soft TPE rubber. We can also add glass fibers to enhance stiffness in materials like ABS and nylon.
Our vacuum casting process typically takes between 7 to 14 days, depending on the complexity of the part and the required finishing services.
Silicone molds used in vacuum casting are typically good for producing 20 or more copies, depending on the part’s complexity and material used.
Vacuum casting is perfect for prototyping, small production runs, engineering models, crowdfunding prototypes, and even end-use parts in some cases. It’s a cost-effective solution for projects requiring high-quality parts without the need for expensive injection molds.
