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A Great Helper for Small-Batch Trial Production: A Guide to Vacuum Casting Materials

Introduction

Vacuum injection molding, commonly known as “silicone remolding,” is a process that uses silicone molds to replicate prototypes in a vacuum environment, allowing for the rapid production of small batches of high-quality plastic parts. Its greatest advantage is the ability to quickly produce prototypes with performance similar to the final molded product without the need for expensive steel molds. The material used for vacuum injection molding is primarily two-component polyurethane (PU), which, through formulation adjustment, can mimic the properties of a variety of engineering plastics.

Introduction to Commonly Used Remolding Materials (PU Resins)

ABS-like Rigid Plastic (ABS-like)

This is one of the most commonly used remolding materials, designed to mimic the comprehensive properties of ABS plastic, offering excellent strength, impact toughness, and ease of post-processing. It is typically opaque but can be customized to off-white, black, and other colors. It is a prime choice for prototyping product housings and structural components.

PC-like Transparent Parts (PC-like)

This material is specifically designed to replicate the high transparency and strength of PC plastic. The finished product has a glass-like transparency and is suitable for prototypes of parts requiring optical effects, such as lampshades, transparent housings, and light guides.

PMMA-like Transparent Parts

Similar to PC-like materials, they also pursue a high-transparency appearance and are used to simulate the texture of acrylic (PMMA). The finished product is crystal clear and is often used for prototypes of exterior models, lenses, or delicate display items.

PP/PE-like Tough Plastics
This material mimics the toughness and bendability of PP or PE, resulting in a brittle finish and a certain degree of elasticity. It is suitable for prototypes of snaps, mechanical parts, or products that require repeated opening and closing, or require toughness.

PA-like Nylon Plastics

This material mimics the wear resistance and toughness of nylon (PA) and is suitable for prototypes of mechanical parts requiring wear resistance, such as gears and sliders.

TPU/TPE-like soft rubber (TPU/TPE-like)
This type of material is specifically designed to simulate the texture of thermoplastic elastomers. The finished product exhibits rubber-like elasticity and softness, with a hardness range from Shore A30 to A90. It is suitable for buttons, seals, anti-slip mats, or prototypes requiring a soft touch.

Silicone Rubber

In addition to using PU materials, overmolding technology can also directly use liquid silicone as the raw material. The finished product is a true silicone part with excellent properties such as high temperature resistance, weather resistance, and biocompatibility. The hardness can be as low as Shore A10-A20, making it suitable for medical-grade product prototypes or applications requiring extreme softness.

Conclusion

Vacuum casting (overmolding) provides great flexibility in design verification through a variety of PU resin formulations. Whether your product requires a hard shell, a transparent lampshade, or soft buttons, you can quickly obtain functional prototypes that are closest to real material properties in a low-cost and high-efficiency manner in the early stages of product development. This is an important tool for accelerating product iteration and time to market.