When it comes to rapid prototyping, vacuum casting is a performance-driven technique. It can be either used with 3d printing, CNC, or independently to speed up product development. So whether you need robust prototypes or main products manufacturing, this technique can meet all your requirements.
If you wonder if this method fits your business or not, then we have you covered. First, dive into some transforming reasons why you should use vacuum casting.
What is vacuum casting?
It’s a casting process for elastomers that use a vacuum to draw liquid material into the mould. This method is ideal to use when manufacturers are facing the issues of air entrapment with the mould. If you need intricate details and undercuts on your products, then this production method fits the purpose. It is also known as thermoforming, as the manufacturing process involves rapid prototyping in which plastic is preheated. Then, the materials are preheated in the vacuum casting machine until they become pliable.
Concept of vacuum casting
The working concept of vacuum casting machines is relatively quick and straightforward. We can divide the working of this method into four easy steps:
Creating master mould
This process needs a high-quality master mould to create multiple copies of the product. The master mould can also be an industrial part, and in addition, you can also use SLA 3d printing service to quickly create a high-quality mould.
Curing process
Once the master mould is ready, it’s encapsulated into a two-part silicone rubber mould. Then the mould is cured at a high temperature to ensure that two parts stick together tightly. In addition, it makes the mould more durable.
Filling the resin
After the mould is prepared, fill it with your desired material, and the resin will replicate the material’s characteristics. Next, the resin material is mixed with metallic powder to achieve the required functional properties. Once the mould is filled, it’s kept in a vacuum chamber to ensure no air bubbles are present.
Cured process
In this process, the resin is kept in the oven at a high temperature to make the material durable and substantial. Once the part is taken out from the mould, it goes for post-processing.
Transforming reasons to use vacuum casting:
You can speed up your manufacturing process by opting for vacuum casting services as they offer several benefits like:
High-grade quality
Vacuum casting is ideal for advanced rapid prototyping services as it delivers you top-notch product quality. This method can replicate hundreds of parts that are of superior quality and share identical geometric properties. The silicone mould holds even the minor detail in the master mould that becomes difficult with other methods.
If you need to produce smaller-sized parts with intricate details, this is your on-the-go method. One thing you need to know is that the final product’s quality depends on the master mould. To achieve the best quality in master mould, additive manufacturing or CNC are ideal methods.
Variety of materials
Similar to a 3d printer, the vacuum casting machine also supports a wide range of industry-grade materials. You can produce parts in a variety of polymer resins including, flexible elastomers, rigid plastics, transparent materials, and more. By using materials like PE/PP or ABS-like polyurethanes, manufactures can gain a robust-quality product. In addition, your vacuum casting prototype can hone the same aesthetic and functional properties similar to the final product.
Functional testing
As the prototypes made using vacuum casting are of high quality and offer accurate mechanical properties, they can be used in various testings. For example, engineers can build a quick prototype that resembles the final product and conduct functional testing and validation. In addition, these parts are also ideas for conducting fit testing if the component is a part of giant machinery.
It is a transforming property of vacuum casting as product developers can carry out QA operations early. When engineers are working on pre-series production, aesthetic and mechanical validations come in handy.
Shorter turnaround time
This process can reduce the overall time-to-market of your product by speeding up the prototyping method. Thus, it can save you both time and resources and keep your manufacturing cycle optimized. On the contrary, other methods like injection moulding use excessive tooling made up of metals, increasing the operational overhead. However, a silicone mould of vacuum casting is easier to make in less than 24 hours.
Advantages of vacuum casting
- Low manufacturing costs
- Customizable mould shapes and sizes
- Highly scalable without quality compromise
- Scope for remaining material recycling is significant
- Faster turnaround time in rapid prototyping
Disadvantages of vacuum casting
- Only a single part is made at a time
- Thick plastic sheets may warp during vacuuming
- Excess moisture can cause unwanted bubbles
- Additional costs are associated with post-processing.
Final thoughts
Vacuum casting is an excellent prototyping method that can fuel your manufacturing setup with higher agility and speed. Scale up your product variety and offer personalization to your customers with this technique. Get started with vacuum casting today and gain a competitive edge.
