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Vacuum Casting

An ideal solution for fabricating high-quality prototypes and small-batch parts for different applications. At Projet, we can fabricate the parts at the highest standard, as well as cost-efficient and with fast turnarounds.

Manufacturing with Vacuum Casting

Also known as urethane casting, is a manufacturing process that provides end-use, rigid, flexible, and rubber parts with production-level quality. The vacuum casting process utilizes a master pattern to create a silicone Mold, an alternative to low-volume injection molding.

Vacuum-cast parts are commonly employed when colour, surface quality, and toughness are paramount. It serves as an ideal alternative for insert molding in low volumes and is compatible with a wide range of materials. Vacuum-cast parts can be clear, colour-matched, painted, have installed inserts, and even custom finishing. We can also add glass fibres to increase the stiffness of ABS and nylon for even more design options.

Advantages :

The vacuum casting process comprises three major steps:

Step 1

The Master Pattern

In the initial step, a master pattern of the final part is created using an additive manufacturing process. We are usually made by 3D Printing or CNC. After finish and inspect the masters, we will move to silicone Mold making.

Step 2

Molding

The second step involves encasing the 3D printed master pattern in liquid silicone, which cures around the pattern. The silicone encapsulates all the features of the printed parts. After curing, the Mold is cut into distinct halves, and the master pattern or 3D printed part is removed, leaving an internal cavity precisely shaped like the desired part.

Step 3

Pouring

The final step of the vacuum casting process involves pouring silicone into the prepared Mold. The Mold is then placed in a chamber to remove air bubbles from the liquid material. For opaque parts, the chamber is typically pressurized, while for clear parts, a vacuum is applied to eliminate bubbles and enhance clarity. Once cured, the silicone halves are separated, and the newly formed part is removed. This process is repeated until the desired quantity is achieved.

Why choose vacuum casting over 3D printing and others?

A crucial differentiation between vacuum casting and 3D printing lies in material performance and quality. Vacuum casting provides access to higher-performing materials that closely emulate those employed in commercial products. Moreover, vacuum cast parts typically exhibit superior fit and finish. If material performance and appearance are paramount considerations for the project, opting for vacuum casting is a highly recommended choice.

3D printing processes, on the other hand, build parts layer by layer from powder or liquid plastic. One of the most significant advantages of 3D printing is that it’s much faster than vacuum casting. If speed and cost are the top priorities, then 3D printing is likely the better option. But vacuum casting is the way to go if the product need high accuracy and detail.

Which is better, between vacuum casting and injection molding?

The choice between the two methods depends on budget, production volume, and product complexity. Vacuum casting is better suited for producing small quantities of complex parts with fine details, while injection molding is ideal in large production runs.

Process capabilityVacuum castingInjection molding
Efficient design stageX
Prototype iterationsX
Large parts
Intricate detailsX
Adapts to modificationX
Tooling costX

Available materials

Silicone is known for its high flexibility and temperature resistance. It is ideal for creating parts with intricate geometries and where high precision is required, such as in the aerospace industry.

Versatile polyurethane plastic resin that is analogous to ABS thermoplastic. Hard, rigid, and impact resistant, it is ideal for different products.

Stiff, transparent urethane resin simulating acrylic. It is hard, with medium to high strength and good clarity for see-through products.

Rigid, high-impact, and clear material with a wide variety of uses. Easy to machine and finish, simulating polycarbonate.

Polyurethane plastic resin, simulating rubber-like materials like TPU, TPE and silicone rubber. Hardness ranging from shore A 20 to 90.

Our competencies

We are a highly dependable mechanical powerhouse with an extensive array of additive & subtractive manufacturing capabilities. Catering from one-off prototyping to low-volume production, we offer solutions that span from basic to industrial, including cosmetic finishing manufacturing.

3D Printing

SLS, SLA, SLM, FDM, MJF

Laser Cutting

CO2 Laser

Vacuum Casting

Urethane Casting

CNC Machining

Milling, Turning

Start your next project with us today

Manufacturing limitless possibilities with industrial fabrication solutions.

Rubber-Like Resin

Rubber-like resin has a low tensile modulus and high elongation at break, making it well-suited for objects that will be bent or compressed.

Suitable for: SLA

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): –
  • Tensile Strength(MPa): 7.9
  • Flex Modulus(MPa): –
  • Elongation(%): 255.1
  • Heat Distortion Temp(°C): –
  • Hardness Shore D: 60-75

ESD-safe (Electrostatic discharge)

It exhibits excellent antistatic performance, making it particularly suitable for fields that require ESD protection.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.08-1.11
  • Tensile Strength(MPa): 35-37
  • Flex Modulus(MPa): 1300-1500
  • Elongation(%): 5-7
  • Heat Distortion Temp(°C): 98
  • Surface Resistance: 107 and 109 ohms Ω

ABS (Acrylonitrile butadiene styrene)

ABS is a lightweight material known for its high impact resistance. These characteristics, coupled with a high heat deflection temperature, render ABS suitable for a wide range of applications and environments.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.06
  • Tensile Strength(MPa): 40
  • Flex Modulus(MPa): 1203
  • Elongation(%): 30
  • Heat Distortion Temp(°C): 73
  • Hardness Shore D: –

PETG (Polyethylene terephthalate glycol)

PETG is a robust material known for its odor neutrality and ease of printing. These characteristics, combined with high impact strength, flexibility, low shrinkage, water resistance, chemical resistance, and high toughness, make PETG an excellent choice for a variety of applications.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: NO
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.27
  • Tensile Strength(MPa): 52
  • Flex Modulus(MPa): 1073
  • Elongation(%): 83
  • Heat Distortion Temp(°C): 64
  • Hardness Shore D: –

TPU (Thermoplastic polyurethane)

TPU material is renowned for its excellent flexibility, high elasticity, tear resistance, wear resistance, cut resistance, sturdiness, and durability.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: NO
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.21
  • Tensile Strength(MPa): 35
  • Flex Modulus(MPa): –
  • Elongation(%): ≥800
  • Heat Distortion Temp(°C): –
  • Hardness Shore D: 95A

Nylon / PA (Polyamide)

Nylon is a versatile material known for its good flexibility, wear resistance, and high strength-to-weight ratio. PA12, in particular, exhibits high toughness and impact resistance.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.21
  • Tensile Strength(MPa): 50
  • Flex Modulus(MPa): 659
  • Elongation(%): 165
  • Heat Distortion Temp(°C): 100
  • Hardness Shore D: –

PC (Polycarbonates)

PC is a high-performance material known for its toughness, heat resistance, dimensional stability, and high optical clarity. It exhibits excellent mechanical properties, high toughness, and impact resistance, making it stable and durable. Additionally, PC offers impressive temperature resistance, with a heat distortion temperature up to 80 ℃.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.21
  • Tensile Strength(MPa): 54
  • Flex Modulus(MPa): 1073
  • Elongation(%): 150
  • Heat Distortion Temp(°C): 80
  • Hardness Shore D: –

ASA (Acrylonitrile styrene acrylate)

ASA shares excellent mechanical properties with ABS but offers additional benefits. It is more resistant to ultraviolet rays and harsh weather conditions, making it particularly suitable for outdoor use. ASA boasts strong toughness, rigidity, and high impact resistance.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: NO
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1
  • Tensile Strength(MPa): 50
  • Flex Modulus(MPa): 4300
  • Elongation(%): 30
  • Heat Distortion Temp(°C): 88
  • Hardness Shore D: –

UL 94-V0

It possesses higher mechanical properties and is halogen-free, environmentally friendly, and flame retardant, achieving a UL94V-0 level flame retardancy. This makes the product more fireproof and safer.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.05
  • Tensile Strength(MPa): 45
  • Flex Modulus(MPa): 2400
  • Elongation(%): 30
  • Heat Distortion Temp(°C): 85
  • Hardness Shore D: –

PLA-CF (Carbon fiber reinforced polylactic acid)

Carbon fibber reinforced PLA, stands out for its remarkable increase in stiffness and strength. This cutting-edge bio-polymer, when combined with recycled carbon fibber reinforcement, results in a higher mechanical properties

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.22
  • Tensile Strength(MPa): 89
  • Flex Modulus(MPa): 3950
  • Elongation(%): 3.2
  • Heat Distortion Temp(°C): 55
  • Hardness Shore D: –

ABS-Like Resin

ABS-like resin excels in high precision, providing a smooth surface quality with exquisite detail features. Known for its superior forming dimensional stability, this resin is ideal for the assembly and testing of various engineering models. Achieving a perfect balance between tensile strength and hardness, it prevents brittleness with its high elongation at break, ensuring resistance to breaking.

Suitable for: SLA

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.05-1.13
  • Tensile Strength(MPa): 42-62
  • Flex Modulus(MPa): 60-80
  • Elongation(%): 11-21
  • Heat Distortion Temp(°C): –
  • Hardness Shore D: 75-80

PAHT-CF (High temperature polyamide carbon fiber reinforced)

A composite of PA and carbon fibre, merges the low water absorption advantage of PA with the high-performance attributes of carbon fibre. This combination yields excellent mechanical and thermal properties that remain robust even in wet conditions. PA+CF is prized for its outstanding chemical resistance, low moisture absorption, and versatile processing capabilities.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.06
  • Tensile Strength(MPa): 125
  • Flex Modulus(MPa): 4230
  • Elongation(%): 1.8
  • Heat Distortion Temp(°C): 194
  • Hardness Shore D: –

PET-CF (Carbon fiber reinforced polyethylene terephthalate)

PET-CF emerges as a superior choice over nylon for printing functional parts in high-humidity environments. Its high-temperature resistance and minimal warping make it ideal for crafting mechanical assembly parts, including automotive accessories and fixtures. In comparison to PETG-CF, PET-CF contains a higher concentration of carbon fibre, resulting in significantly greater strength and high temperature resistance.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.29
  • Tensile Strength(MPa): 131
  • Flex Modulus(MPa): 5320
  • Elongation(%): 1.2
  • Heat Distortion Temp(°C): 205
  • Hardness Shore D: –

PEEK (Polyether ether ketone)

PEEK (polyetheretherketone) is a high-performance semi-crystalline industrial thermoplastic known for its exceptional resistance to harsh chemicals, minimal moisture absorption, excellent fire performance, superior mechanical strength over a wide temperature range, and reliable dimensional stability.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.29
  • Tensile Strength(MPa): 100
  • Flex Modulus(MPa): 4200
  • Elongation(%): 40
  • Heat Distortion Temp(°C): 140
  • Hardness Shore D: –

PEI (Polyetherimide)

PEI is a high-performance industrial-grade thermoplastic known for its strength, durability, and low flammability. This versatile material finds applications in various industries, including automotive, aerospace, medicine, and dentistry.

Suitable for: FDM

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: NO
  • Automation: YES
  • Medical: NO
  • Education Community: NO

Material Property

  • Density(g/cm3): 1.34
  • Tensile Strength(MPa): 54
  • Flex Modulus(MPa): 2170
  • Elongation(%): 3
  • Heat Distortion Temp(°C): 158
  • Hardness Shore D: –

General Resin

General resin, known for its high rigidity, proves to be a versatile material ideal for both functional testing and rapid prototype.

Suitable for: SLA

Application

  • Prototype

Application Fields

  • Aerospace: NO
  • Automotive: YES
  • Industrial Machinery: NO
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.08-1.13
  • Tensile Strength(MPa): 46-67
  • Flex Modulus(MPa): 46-72
  • Elongation(%): 28-36
  • Heat Distortion Temp(°C): –
  • Hardness Shore D: 78-82

High Temp. Resin

High Temp Resin is characterized by high hardness, strength, modulus, and precision. It exhibits resistance to prolonged heating at 120°C or boiling at 100°C, showcasing excellent mechanical properties, weather resistance, and temperature resistance.

Suitable for: SLA

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: NO

Material Property

  • Density(g/cm3): 1.09-1.10
  • Tensile Strength(MPa): 70-85
  • Flex Modulus(MPa): 95-105
  • Elongation(%): 35-40
  • Heat Distortion Temp(°C): 100.5
  • Hardness Shore D: 82-84

Hard-Tough Resin

This hard resin boasts higher toughness and impact resistance compared to standard ABS-like resin, making it exceptionally well-suited for mechanical prototypes.

Suitable for: SLA

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.08-1.12
  • Tensile Strength(MPa): 30-60
  • Flex Modulus(MPa): 30-75
  • Elongation(%): 35-52
  • Heat Distortion Temp(°C): 60
  • Hardness Shore D: 75-81

Nylon-Like Resin

Nylon-like resin is a high-strength material known for its excellent durability and long-term stability. It also boasts exceptional toughness and impact resistance.

Suitable for: SLA

Application

  • Prototype
  • End-User part

Application Fields

  • Aerospace: YES
  • Automotive: YES
  • Industrial Machinery: YES
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: YES
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.05-1.15
  • Tensile Strength(MPa): 68
  • Flex Modulus(MPa): 35
  • Elongation(%): 15
  • Heat Distortion Temp(°C): –
  • Hardness Shore D: 75

PLA (Polylactic acid)

PLA is an environmentally friendly biopolymer-based material that is both stiff and easy to print. It is available in a wide variety of colours.

Suitable for: FDM

Application

  • Prototype

Application Fields

  • Aerospace: NO
  • Automotive: YES
  • Industrial Machinery: NO
  • Consumer Electronics: YES
  • Automation: YES
  • Medical: NO
  • Education Community: YES

Material Property

  • Density(g/cm3): 1.23
  • Tensile Strength(MPa): 60
  • Flex Modulus(MPa): 1973
  • Elongation(%): 20
  • Heat Distortion Temp(°C): 53
  • Hardness Shore D: –