Reproduction in Vacuum Casting
From the original model to a market-ready small series
Every innovation begins with an idea – but the real added value only becomes apparent when it is implemented efficiently and reliably. With vacuum casting from 1zu1scale, high-quality plastic parts can be produced quickly – from prototypes and small series to market-ready custom-made products. Thanks to modern manufacturing technologies, precise master models, and many years of experience, precisely fitting parts can be produced at moderate initial costs. This means that products can be tested, adapted, and brought to market more quickly. At the same time, the process allows for flexible adaptation during the pilot phase.
Fast Small Series with Vacuum Casting from 1zu1scale
State-of-the-art equipment, precise master models, and our expertise ensure components that are true to form, color, and function, which can be reproduced in a matter of days or weeks—up to 1,000 series parts from a single silicone mold. Without lengthy tool development, you receive cost-effective, high-quality plastic parts that bring your products to market faster.
Solid, malleable, and functional
Vacuum casting is the ideal solution for manageable quantities of fully functional plastic parts. 1zu1scale has been perfecting this process since 1996. We manufacture dimensionally accurate components with high repeatability, even for complex geometries, on more than 20 modern systems.
Each part is individually inspected, sanded, and polished after casting. Painting, printing, or individual coloring can be provided on request. Around 50 materials are available—from PUR to PUR rubber to silicone—for hard, elastic, transparent, biocompatible, food-safe, heat-resistant, or flame-retardant parts. Additives such as glass or carbon fibers increase strength. Inserts such as bushings, magnets, or sensors can be integrated directly. Multicolor or multi-part components, partial refinements, and complete assemblies including installation are easily possible.
Fast to Market – with maximum Flexibility
Depending on the complexity of the component, vacuum casting at 1zu1scale enables turnaround times ranging from a few days to around three weeks. Near-series components are ideal for pilot phases, validations, or gradual market launches.
Design changes and optimizations are possible during the pilot phase—without new tools and at comparatively low cost. For annual requirements of up to 1,000 units, vacuum casting is one of the most economically attractive manufacturing solutions. As a full-service provider, 1zu1scale accompanies the entire process – from the master model to the silicone mold to the finished small series – discreetly, efficiently, and with the highest quality standards.
Vacuum Casting at a Glance
- Immediate production of near-series plastic parts with low initial costs
- Full-service provider: master model and series part from a single source
- Ideal for market-ready small and pre-series production
- Two-component parts and material combinations possible
- Wide variety of materials: hard, soft, transparent, biocompatible, food-safe, heat-resistant, flame-retardant, rubber-like
- Surfaces & finishes: textured, high-gloss, painted, printed, laser-marked, hot foil stamping
- Precise post-processing and assembly of complete assemblies
Technical Key Figures
- Up to 1,000 series parts from a silicone mold
- First components available in approx. 5 working days
- Maximum component size: 1,000 × 1,200 × 1,000 mm
- Maximum casting volume: 25,000 ml
- Wall thicknesses from 0.5 mm (depending on geometry)
- 50 materials available
- PUR components: 70–122 Shore D
- PUR rubber: 30–85 Shore A (13 gradations)
- Silicone: 10–65 Shore A