Replication Without Metal Tooling
Vacuum casting is a manufacturing method in which a master model—produced by CNC machining, 3D printing, or provided by the customer—is molded using silicone rubber, and urethane or epoxy resin is then poured into the mold to create duplicate parts. By using silicone molds, this process enables the production of highly precise replicas, capable of reproducing even fine surface details such as fingerprints. We mainly handle urethane resins, with material options equivalent to ABS, PP, and rubber-like urethane, allowing us to select the most suitable material according to the intended application. Vacuum casting is an ideal solution for short lead-time prototyping and for customers seeking cost-effective resin replicas. 【Key advantages include】 ・Excellent cost performance and short delivery times ・Ability to replicate surface textures such as matte finishes and color details from the master model ・Colored urethane resins enable prototype production without painting ・Support for silicone molding, urethane rubber molding, two-color molding, and insert molding Through this process, we can deliver resin replicas that faithfully reproduce the shape and texture of the master model, while maintaining an optimal balance between cost and lead time. 【About Materials】 ■ Urethane and epoxy products made with silicone molds (equivalent to ABS, equivalent to PP, urethane rubber) ■ Silicone products made with resin molds
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basic information
■Comparison with CNC Machining and SLA 3D Printing Unlike CNC machining or SLA 3D printing, vacuum casting is well suited for small-lot replication and for producing multiple parts with varied colors and material properties. It allows efficient verification of design intent and appearance while keeping both cost and lead time under control.
Price range
Delivery Time
P3
Applications/Examples of results
■Automotive Industry ・Visual evaluation and pre-production verification of resin parts ・Multiple material and geometry prototype comparison models ■Medical Device Industry ・Evaluation models of transparent and elastomeric components ・Prototype parts for testing equipment and inspection jigs ■Home Appliances / Office Equipment ・Appearance and usability confirmation models ・Prototypes for marketing and promotional purposes, including color and texture ■Industrial Machinery & Equipment: ・Replicated parts for mechanism verification and durability evaluation ・Duplication of replacement and spare parts ■Research & Educational Institutions: ・Models of components for experimental apparatus ・High-accuracy replica models for evaluation and analysis ■Exhibitions & Promotional Use ・Prototypes for display at shows and events ・Appearance models that simulate mass-production products
Detailed information
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Coloring Beyond the Master Model In addition to replicating the original master model, it is also possible to add color directly to the casting urethane resin, even if the master model itself is uncolored. This allows for color verification and appearance evaluation without the need for post-painting.
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Urethane Rubber and Silicone Parts Are Also Available We can also produce parts using urethane rubber and silicone materials. Urethane rubber: Adjustable hardness range from Shore A 20° to 90° Silicone: Adjustable hardness range from Shore A 30° to 60° Both materials can be colored as required For silicone molding, the achievable production quantity depends on the mold material; when using PMMA molds, up to approximately 200 parts can be produced. These processes are commonly used for wearable product development prototypes, as well as packings, air valves, and other functional rubber components.
Company information
We are a comprehensive prototyping support company that provides end-to-end solutions, from industrial product design and engineering to prototyping and mass production—all within a single organization. By accurately understanding our customers’ concepts and ideas, we apply the most appropriate methods at each development stage to bring products to life exactly as envisioned. With machining at the core of our capabilities, we offer a wide range of manufacturing processes supported by highly skilled engineers, enabling production with various materials including resins, metals, and rubber. We deliver high-precision prototypes and functional parts that meet stringent quality requirements. In addition, we operate approximately 60 machining units, allowing us to respond flexibly to short lead-time projects and urgent requests. We also support mold-free mass production, helping to accelerate development timelines while optimizing overall costs.
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