Capabilities / Vacuum Casting Services

ZY Vacuum Casting Services: Low-Volume Plastic Prototypes

perfect solution for production quality parts
Your professional and reliable partner

ZY Vacuum Casting

Vacuum Casting, also called silicone mould, is a manufacturing process to make the mold in silicone from a master model, and then cast the parts out from polyurethane, transparent polyurethane, ABS and other materials under vacuum, to achieve the strength and hardness of ABS and other materials. The parts can be casted according to the color required by customers.

Vacuum Casting is the best replacement of injection molding for low volume products. Casting material hardness and strength is very close to the injection molding material. Vacuum casting is a very low-cost and fast way to make prototypes if you want 20 to 100pcs of parts.

Advantages of Vacuum Casting

Fast turnaround

Usually 2 weeks or less to make parts ready

Surface finish options

Different Colors, Textures & Finishes Available

Economical in both cost and time

Silicone molds are less expensive than metal tools, but more easier and faster to make

Repeatability

Silicone molds can be used around 20 times before replacing

large part making capacity

Very large parts can be produced shortly, supported by large vacuum casting machine

Excellent Physical Propertie

The casting parts have good Physical Properties for functional purpuse

Casting Resin Material Available

Casting resins are polymers with a wide range of properties and use. Zhiyou offers different kinds of casting resins materials to meet your applications, including Axson from France and Hei-Cast from Japan. Materials with certain properties are similar to engineering production plastics, such as ABS, PMMA, PC, PP, PA, etc. Some special materials are also available, like high-temperature resistant (120℃ or 200℃) or fire-resistant (UL94-V0).

Vacuum-Casting-Casting-Resin-Material-Available

Our Vacuum Casting Capability

How It Works (3 steps)

Step 1. Master model building– CNC machined or 3D printed via SLA or SLS

Step 2. Silicone mold making – liquid silicone is poured around the master model and fully cured. Once dried, the mold is cut open and master is removed

Step 3. Casting parts – the casting resin is poured into the cavity to create products, like replicate


Detailed step as below

CNC Machining Parts

Fullsize image
±0.02mm
Tolerance
20+
Machines
6 Days
Samples Delivered
ISO
13485, 16949, 14001

ZY VACUUM CASTING Vacuum Casting Capabilities

Swipe to scroll
Feature Description
Tolerance At ZY VACUUM CASTING, replicated casts follow ISO-2768-CL standards. Local tolerances can reach ±0.15mm, and small holes can achieve up to ±0.10mm precision.
Color and Finishing Supports a wide range of colors, transparency levels, and surface finishes.
Maximum Part Size Up to 2.3 × 1.3 × 0.6 meters.
Daily Capacity Up to 200 pieces per day.
Lead Time Lead time varies based on part complexity and order volume. The full process includes prototype making, silicone mold creation, casting, and finishing. Simple single parts can ship in under 5 days, but larger batches may require more time depending on the project.

From Prototyping to Production

Moving from initial concepts to market-ready products, ZY VACUUM CASTING’s vacuum casting services offer cost-effective solutions for your product development.

Concept Validation

Quickly turn early designs into real parts using 3D printing. Great for checking size, shapge, and surface finish before moving forward. No need for hard tooling at this stage.

Prototyping

Make 1 to 100 functional vacuum cast prototypes for testing fit, strength, and usability. Materials and tolerances are close to final production.

SLow Volume Production

Perfect for low-volume runs, product launches, or bridge production. Cast 20 to 200+ parts with consistent quality and quick turnaround—skip the wait for injection molds.

Mass Production

For larger production needs, we offer injection molding to create high-volume plastic parts with consistent quality and lower unit cost.
Vacuum Casting Overview Vacuum Casting Types and Profiles Materials Finishes Applications Advantages and Disadvantages
Vacuum Casting Overview Vacuum Casting Types and Profiles Materials Finishes Applications Advantages and Disadvantages


What is Vacuum Casting?

Vacuum casting is a precision manufacturing process used to create high-quality plastic or rubber parts in small to medium production runs. By utilizing a vacuum to draw liquid material into a silicone mold, this technique produces detailed, consistent components that closely replicate the original master pattern. Ideal for prototyping and low-volume production, vacuum casting offers a cost-effective alternative to injection molding, with faster turnaround times and exceptional surface finish capabilities. Common applications include automotive parts, medical devices, and consumer electronics components, where accuracy and aesthetic quality are critical.

Vacuum Casting With ZY VACUUM CASTING

At ZY VACUUM CASTING, our vacuum casting services combine advanced technology with expert craftsmanship to deliver superior results for your project. We specialize in producing complex parts with tight tolerances, using state-of-the-art vacuum casting equipment and high-grade materials. From rapid prototyping to bridge production, our process ensures:

  • Precise replication of intricate details (down to 0.1mm accuracy)
  • A wide range of material options, including polyurethanes, silicones, and rubber-like compounds
  • Custom finishes (painting, plating, texturing) to match your specifications
  • Fast lead times (as little as 3-6 days for small batches)
  • Whether you need functional prototypes or end-use parts, ZY VACUUM CASTING’s vacuum casting solutions scale with your needs, reducing costs without compromising quality.

    • Ready to get started on your Vacuum Casting Service?



    Types of Vacuum Casting

    Vacuum casting encompasses several specialized techniques tailored to different materials and applications:

  • Polyurethane Vacuum Casting: The most common type, using two-part polyurethane resins to create rigid or flexible parts. Ideal for mimicking the properties of engineering plastics (ABS, PP, PC).
  • Silicone Vacuum Casting: Uses liquid silicone rubber (LSR) to produce heat-resistant, flexible components. Suitable for gaskets, seals, and medical devices.
  • Rubber Vacuum Casting: Focuses on elastomeric materials, delivering parts with high durability and elasticity, often used in automotive and industrial seals.
  • Overmolding Vacuum Casting: Combines multiple materials (e.g., rigid plastic with soft rubber) in a single process, enabling complex, multi-material parts.

    • Ready to get started on your Vacuum Casting Service?



    Materials for Vacuum Casting

    Vacuum casting supports a diverse range of materials to match specific functional requirements:

    • Polyurethanes: Available in rigid (Shore D 60-85), flexible (Shore A 30-90), and foam variants. Resistant to impact, chemicals, and UV exposure.
    • Silicone Rubbers: Heat-resistant (up to 200°C), biocompatible, and excellent for electrical insulation. Ideal for medical tools and high-temperature applications.
    • Thermoplastic Elastomers (TPE): Offer rubber-like elasticity with plastic processability, suitable for grips, gaskets, and wearables.
    • Epoxies: Provide high strength and dimensional stability, often used for structural components and electronics housings.

    Each material can be customized with additives for flame resistance, conductivity, or color matching.

    Ready to get started on your Vacuum Casting Service?

    Finishes for Vacuum Cast Parts

    Vacuum cast parts can be enhanced with a variety of finishes to meet aesthetic and functional needs:

    • Painting: Custom colors, gloss/matte finishes, and texture coating (e.g., soft-touch, metallic).
    • Plating: Chrome, nickel, or gold plating for a decorative, corrosion-resistant surface.
    • Texturing: Mold-in patterns (brushed, embossed, or custom designs) for improved grip or branding.
    • Polishing: High-gloss finishes for cosmetic parts, achieving a mirror-like surface.
    • Vapor Deposition: PVD coatings for enhanced hardness and wear resistance, ideal for industrial components.


    Applications of Vacuum Casting

    Vacuum casting is widely used across industries for its versatility and precision:

  • Automotive: Prototyping interior trim, dashboard components, and rubber seals.
  • Medical Devices: Producing custom enclosures, surgical tools, and biocompatible parts.
  • Consumer Electronics: Creating phone cases, wearables, and cable management components.
  • Aerospace: Low-volume production of lightweight, high-strength parts for drones and aircraft.
  • Toys & Recreation: Manufacturing detailed figurines, game pieces, and durable outdoor equipment.

    • Ready to get started on your Vacuum Casting Service?



    Advantages & Disadvantages of Vacuum Casting

    Advantages:

    • Cost-effective for small batches (10-500 units) compared to injection molding.
    • Fast turnaround (molds ready in 1-2 days, parts in 3-6 days).
    • High detail replication, including fine textures and complex geometries.
    • Wide material selection to match end-use properties.
    • No tooling costs for low-volume runs (silicone molds are reusable 20-50 times).

    Disadvantages:

    • Cost-effective for small batches (10-500 units) compared to injection molding.
    • Fast turnaround (molds ready in 1-2 days, parts in 3-6 days).
    • High detail replication, including fine textures and complex geometries.
    • Wide material selection to match end-use properties.
    • No tooling costs for low-volume runs (silicone molds are reusable 20-50 times).

    Ready to get started on your Vacuum Casting Service?

    Ready to get started on your Injection Molding project?

    Free shipping available for domestic CNC orders