Polyurethane Vacuum Casting

From 1 to 50+ Parts

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Vacuum Casting – Urethane Casting

RJC is fully equipped to handle your vacuum casting and silicone forming needs. With years of expertise in the field, we can manufacture your plastic parts to the highest standards, cost-effectively and with quick turnaround. Ideal for high-quality prototyping, functional testing, concept proofing, and showcase demos. Polyurethane castings can range from a few to several hundred as needed.

We can provide a complete solution for creating master models and casting copies from your CAD designs. We not only manufacture high-quality molds, but also provide a full range of finishing services including painting, sanding, pad printing, and more. We’ll help you create parts for showroom quality display models, engineering test samples, crowdfunding campaigns, and more.

Tips For ABS Plastic Injection Molding

What is vacuum casting?

Vacuum casting is a manufacturing technique that uses a vacuum to draw liquid casting material into a mold. It differs significantly from injection molding, which uses a screw to push a liquid material into a mold.
The vacuum casting process has significant advantages, especially for parts with undercuts or fine details.
The process starts with a master model, which RJC creates using one of its CNC machining centers – although 3D printing is also available. This master model is then dipped in liquid silicone, cured and made into a mold.
Once it’s been cut and the master model removed, the silicone mold is ready to use. This stage involves pouring the casting resin into the mold as the vacuum removes air bubbles and air pockets to ensure a smooth surface.
The resin part is then cured in an oven, cooled and removed from the silicone mold, which can be reused about 20 times.
Each casting is an exact replica of the original master model. It is the perfect solution for rapid prototyping and low-volume manufacturing of high-quality parts.

What is Polyurethane Casting​​​?

Polyurethane castings provide end-use, rigid, flexible and rubber parts with production-grade quality. The polyurethane casting process uses a 3D printed master model to create a silicone mold that provides high-quality, short-run parts as an economical alternative to injection molding in small batches.

How Polyurethane Casting Works
Polyurethane casting is similar to injection molding in that it requires a tool with a cavity in the final part shape. The main difference is that polyurethane casting uses a “soft” mold made of silicone, while injection molding uses a CNC machined “hard” metal mold. Therefore, the disadvantage of polyurethane casting is that the mold wears out faster. However, it is much more cost-effective for low-volume and prototype plastic parts that require production-grade quality and surface finish.

Tips For ABS Plastic Injection Molding

RJC Casting Services Low Volume, Durable Parts with Production-Level Quality

Advantages Of Vacuum Casting
  • Low cost for molds
  • Molds can be made in a few days
  • Many types of polyurethane resins are available for casting, including overmolding
  • Cast copies are highly accurate with excellent surface texture
  • Molds are durable for 20 or more copies
  • Perfect for engineering models, samples, rapid prototypes, bridge to production
Benefits Of Urethane Casting

Urethane casting has a low-cost and quick turnaround for high-quality plastic parts compared to injection molding or 3D printing. Where injection molding requires an expensive upfront investment for the machining of the mold, the silicone mold required for urethane casting is inexpensive and easy to produce. Additionally, while most 3D printing processes require extensive post-processing to get to a near-finished state, urethane cast parts come out of the mold ready to go. Urethane casting is an excellent choice for creating high-quality prototypes or low-volume production of rigid, flexible, clear, colored, or rubber-like plastic parts.

See Our Past Projects

injection molding
 Telehealth Hub Medical Device

The ProEx Telehealth Hub by VisionFlex is a great example of a successful collaboration between product developer and manufacturer. We worked closely with VisionFlex to optimize their design in order to produce a showroom-worthy prototype. Learn how we did it in this case study. Read more…

injection molding
Vacuum Casting Smart Sensors

SKIIN is an innovative line of smart clothing developed by the Canadian company Myant. Small, light and sophisticated sensors are housed in discrete cases, made with the help of Star Rapid’s vacuum casting service. See how we helped them bring SKIIN to life. Read more…