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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■ High Precision Down to Fingerprint Detail Vacuum casting achieves exceptional precision, capable of reproducing even fingerprint-level surface details. Surface textures such as matte finishes on the master model can be faithfully replicated in the final product.
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■ Coloring Options Beyond the Master Model The casting material itself can be pigmented, eliminating the need for post-molding painting processes. Two-color molding is also available, allowing for greater design flexibility and functional evaluation.
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■ Adjustable Hardness with Vacuum Casting By adjusting the curing agent formulation, the hardness of the final product can be precisely controlled. Urethane rubber is available in a hardness range of 20° to 90°, while silicone ranges from 30° to 60°. Multiple hardness variations can be produced for comparison and testing, making this method ideal for wearable device development as well as prototype parts such as gaskets and air valves.
Company information
We are a comprehensive prototyping company providing end-to-end solutions, from industrial 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 suitable methods at each stage of development to bring products to life as envisioned. With machining at the core of our capabilities, we offer a wide range of manufacturing processes supported by highly skilled engineers, working with various materials including plastics, metals, and rubber. We deliver high-precision prototypes and functional parts that meet stringent quality requirements. In addition, we operate approximately 60 machining units, enabling us to respond flexibly to short lead times and urgent requests. We also support mold-free production, helping accelerate development timelines while optimizing overall costs.
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