Specially designed for “customized” and “small batch” parts processing
Vacuum casting is a specialized technique that uses precise silicone molds made from a 3D-printed or CNC-machined master model, often referred to as silicone molding or soft tooling. This method involves casting polyurethane (PU) parts under vacuum conditions, ensuring bubble-free production and accurate reproduction of fine details with minimal tolerance deviations. Compared to CNC machining, vacuum casting is faster and more cost-effective for producing multiple identical parts.
Our silicone molding services can be customized to meet client needs, including specific color requirements during the molding process. We can also integrate other components into the mold (e.g., rubber over plastic or soft material over hard material) to enhance the product’s quality and feel.
Advantages of the Process:
⚡ High Precision: Achieves fine surface detail, replicating the aesthetic quality of injection-molded parts.
⚡ Cost Efficiency: Minimizes the time and cost of traditional manufacturing processes, accelerating the product development cycle, making it ideal for small-batch production. (Each mold can produce up to 15-25 pcs)
⚡ Versatility: Supports a wide range of materials, colors, and surface finishes, catering to customer customization needs.
Soft Tooling Mold
Assembled Prototype
| Soft Tooling (vacuum casting) | Reaction Injection Molding (Low pressure injection) | Rapid Tooling / Injection Molding (aluminum mold or soft steel mold + mass production injection) | |
|---|---|---|---|
| Mold material | RTV Silicone (Soft Mold) | Silicone, FRP/GRP, Aluminum Powder Epoxy Resin | Aluminum alloy/mild steel P20, S50C, NAK80, etc. |
| Mold cost (relative) | $ | $$ | Aluminum Mould $$$ / Steel Mould $$$$$ |
| Mold delivery time (general situation) | 3 – 7 working days | 5 – 15 working days | 15 – 35 working days |
| Single mode life | 15 – 25 pieces | 50 (Silicone) – 3,000 pcs (Aluminum Powder Epoxy Resin) | Aluminum moulds 10,000 – 20,000 pieces Steel moulds 100,000 – 500,000 pieces |
| Cavity pressure/ Clamping force | Vacuum → 0.05 MPa / Almost no clamping | 0.3 – 1 MPa / 5 – 30 ton | 70 – 200 MPa / 75 – 800 tons |
| Common materials for finished products | * PU (ABS‑like, PC‑like, transparent PMMA‑like) * High heat resistant PU (120 °C) * Elastomer PU / Silicone (Shore A 30‑90) * Conductive, flame retardant, filling grade special resin | * Solid or micro-foamed PU / PUA * Glass fiber reinforced PU (RRIM / SRIM) * DCPD, Nylon-RIM (Caprolactam) * Reactive EP, Polyester | * ABS, PC, PC/ABS, PP, PE, POM, PBT * PA6 / PA66 (including GF, CF) * PMMA, ASA, TPU/TPE and other thermoplastics |
| Cycle time/piece | 30 – 60 min | 2 – 5 min | 20 – 60 s |
| Recommended ordering batch | 8 items↑ | 50 items↑ | 5,000 pieces↑ (MOQ 5,000 pcs) |
| Common size range | ≤ 0.5 m | ≤ 2 m Large enclosures possible | ≤ 1 m; potentially limited by the clamping force of the injection molding machine |
| Possible wall thickness | 1 – 6 mm; uniform thickness is the most stable | 2 – 20 mm, thick and thin can be mixed | 0.8 – 4 mm; thickness difference requires flow channel balance |
| Dimensional accuracy | ±0.20 mm /100 mm | ±0.15 mm /100 mm | ±0.05 mm /100 mm |
| Surface quality | 0.1 mm texture can be copied; spray painting is required | Available in Class-A paint or leather texture | The mold surface can directly achieve mass production texture or high gloss |
| Typical advantages | Low mold opening fee, fast delivery, high flexibility | Low mold cost, large size, mixed thickness, impact resistance | Lowest unit cost, best precision, most materials and colors |
| Common Applications | Appearance/functional prototypes, samples, small batch internal components | Automobile bumpers, medical/industrial large panels, structural foam parts | Mass production of consumer goods, precision gears, fasteners, and large-volume structural parts |
Scope of Services
We create realistic product models or prototypes based on customer-provided requirements and drawings. These models accurately replicate the intended design, allowing for detailed evaluation and testing before moving to mass production.
We can achieve small-scale batch production of identical parts, with the master mold having a lifespan of producing 15 to 25 pieces.
We provide just-in-time production based on customer needs, minimizing storage and inventory costs. This approach ensures efficient production while reducing overhead related to warehousing and excess stock.
Basic Processing Materials
Plastics
Rubber is valued for its flexibility and shock-absorbing properties, making it ideal for products like seals or gaskets that need to withstand continuous bending and pressure. We can also adjust the hardness of the rubber to meet specific requirements.
ABS is strong, durable, and offers good heat resistance and impact resistance, making it a preferred plastic for general parts and consumer products.
PC (Polycarbonate) is highly durable, offering excellent impact resistance and good transparency.
PP (Polypropylene) is tough and offers excellent chemical resistance, making it commonly used in parts and packaging that come into contact with chemical solvents.
CMF Options
We provide a wide range of materials, including metals, plastics, and composites.
We offer superior surface finishes that enhance part durability and aesthetics for applications requiring smooth or textured surfaces.
Applied Industries
IDMockup offers top-notch manufacturing capabilities, whether for rapid prototyping or custom production orders. Our self-owned factories and satellite factories are equipped to efficiently produce complex, high-quality parts.
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