Urethane Casting & Vacuum Casting | Precision Polyurethane Parts
Rapid Urethane Casting | High-Quality, Low-Volume Production
Our urethane casting process begins with creating a precise master pattern. This pattern can be produced using various methods, including CNC machining or 3D printing. A high-quality silicone mold is then crafted from this master, capturing intricate details with exceptional accuracy.
Liquid polyurethane resin is carefully poured into the silicone mold under vacuum conditions to eliminate air bubbles. This ensures the creation of flawless, high-quality parts. Once the resin cures, the finished urethane product is extracted from the mold.
Prototeque: Urethane Casting Capabilities
Our 3 advanced urethane casting machines enable us to produce large-scale parts up to 1500mm x 1000mm with exceptional precision. Achieve tight tolerances of L<200mm ±0.3mm and L>200mm ±0.1%xL for your critical components.
Prototeque: Urethane Casting Material Options
Our urethane casting expertise allows us to bring your ideas to life with a wide range of materials. From the flexibility of soft rubber to the rigidity of ABS-like options, we offer:
- Elastomers: Soft, hard, and silicone rubber for flexible components.
- Plastics: ABS-like, ABS+PC-like, PC-like, PMMA like and PP-like materials for durable parts.
- Engineered Materials: Nylon+30% glass fiber like, POM
The Vacuum Casting Process: A Step-by-Step Breakdown
Step 1: Master Pattern Creation
The master pattern is a replica of the 3D model, but it is made from a more durable material, such as metal or resin. The master pattern is used to create the silicone mold, which will be used to cast the final product.
there are two main ways to build the master pattern ( CNC machining and 3D printing).Choose between CNC machining or 3D printing for your master pattern based on precision, speed, and cost.
CNC offers superior accuracy but is slower and more expensive. 3D printing is faster, cheaper, and ideal for prototyping, but may compromise precision. Consider your project’s specific needs to select the best method.
Step 2: Silicone Mold Production
To create a silicone mold, the master pattern is first secured within a sealed metal or bakelite container.
Liquid silicone rubber is then poured around the pattern, filling the container.
The sealed container is placed in an oven and cured for approximately 20 minutes.
Once cured, the silicone mold is removed from the container, leaving behind a precise replica of the master pattern.
Step 3: Resin Mixing and Pouring
- Mix the two parts of the polyurethane resin in a specific ratio according to the manufacturer’s instructions.
- Place the mixed resin in a cup or container and place it into a urethane casting machine.
- Place the urethane casting mold into the machine and activate the vacuum function. This process removes air bubbles from the mold and ensures a smooth, bubble-free finish. The vacuum process typically takes around 30 minutes.
- Once the vacuum is complete, the machine will pour the mixed polyurethane resin into the urethane casting mold. The resin will fill the mold and cure, creating the final product.”
Step 4: Part Removal
Once the resin has cured, the silicone mold is opened, and the final product (a urethane molded part) is removed.
Urethane molded parts often have flashes or burrs that need to be removed through trimming or deburring processes.
The silicone mold can typically be reused to create 20-30 copies of the product before it may require maintenance or replacement.
Step 5: Finishing
The final stage in the vacuum casting process is to finish the parts. This may include sanding, polishing, and, depending on the customer’s specifications, painting. All parts, whether painted or not, are typically polished before shipment to ensure a smooth and visually appealing finish.