Vacuum casting is a proven process for the economical production of near-series plastic components. Plastic vacuum casting offers an ideal alternative, especially for increasing quantities where traditional toolmaking is not yet cost-effective.
In plastic vacuum casting, a precise master model serves as the basis for a flexible silicone mold. We use this mold to produce high-quality components from polyurethane casting resins under vacuum. Controlled casting in the vacuum chamber prevents air pockets and achieves consistent, reproducible results – perfect for functional prototypes, pre-series and small series. Precision components made of PU, silicone and rubber. Ideal for prototypes, pre-series and small series.
Series Production in Vacuum Casting
Vacuum casting plastic enables short turnaround times and a high degree of design freedom. Thanks to modern materials, properties can be achieved that are very similar to those of injection-molded parts. Depending on requirements, we manufacture a small number of components or small series, right up to near-series production.
Different materials are used depending on requirements. Our sales team will be happy to provide you with detailed information and individual advice on materials such as polyurethane (PU), special PU resins, PU rubber, and silicone in vacuum casting. Vacuum casting is typically used for functional prototypes, pre-series, small series, as well as replacement and special parts.
Overview of Materials
Polyurethane (PU) – Standard Material
Used primarily for housings, covers, and functional plastic components.
Special PU Resins – for increased Requirements
For special mechanical, thermal, or optical requirements.
Silicone & Rubber – for maximum Flexibility
From seals and hoses to protective caps and shock absorbers – manufactured in Shore hardnesses from 10 to 85 Shore A.
High Precision thanks to reinforced Silicone Molds
The silicone molds used here form the basis for all types of vacuum casting—regardless of whether PU standard resins, PU special materials, PU rubber, or silicone are used.
Our specially reinforced silicone tools are an essential quality factor in vacuum casting. By using high-strength additives, we increase:
- The dimensional accuracy of the components
- The service life of the molds
- The reproducibility of the results
While classic silicone molds often reach their limits after 15–20 castings, our optimized molds enable significantly higher quantities—up to 1,000 parts per mold with standard PU resins. The initial costs are incurred only once, and the mold remains usable for further production runs.
Our Vacuum Casting Technologies at a Glance
- Vacuum casting PUR hard
Series-like mechanical properties - Vacuum casting PUR special materials
Options for heat, fire, food, and UV resistance - Vacuum casting PUR rubber
Elastomer parts from 30 to 85 Shore A - Vacuum casting silicone
Silicone components from 10 to 65 Shore A
Your Advantages with Vacuum Casting at 1zu1scale
- 1 mold = up to 1,000 parts (with standard PU resins)
- One-time initial costs, ideal for economical series production
- Wide range of materials: hard, soft, transparent, clear, or colored plastics
- Diverse surface options: textured, high-gloss, spray putty, and much more
- Additives can be used, e.g., glass fiber to increase strength
With our experience in vacuum casting plastics, we accompany your project from the initial idea to series production.
FAQs about Vacuum Casting
Vacuum casting is a casting process in which plastic is poured into silicone molds under vacuum. This produces high-quality, virtually bubble-free components.
Injection molding requires expensive metal tools and is only worthwhile for large quantities. Vacuum casting plastic is more flexible, faster, and more cost-effective for prototypes, pre-series, and small series.
Polyurethane casting resins, silicones, and elastomer-like materials in various hardnesses, colors, and properties are used.
With reinforced silicone molds, up to 1,000 components per mold are possible, depending on the material.
Vacuum casting is suitable for mechanical engineering, automotive, medical technology, electronics, model making, and apparatus engineering, among others.