About Vacuum Casting/Urethane Casting:
Urethane Casting Process
Urethane casting (vacuum casting) transforms liquid resins into high-fidelity plastic or rubber parts using silicone molds—perfect for prototypes or low-volume batches. Our ISO-certified process delivers ±0.10mm tolerances and production-ready finishes in just 5 days.
Digital-First Master Patterns
Upload your CAD to our intuitive dashboard for instant DFM feedback—no design delays. We craft master patterns via:
- ⇒ Precision 3D Printing (24 hr): SLA/DLP for complex geometries (±0.05mm).
- ⇒ CNC Machining (48 hr): Ideal for ultra-tight tolerances (±0.020mm).
- ⇒ Your choice: speed (3D) or precision (CNC). We optimize drafts, wall thickness, and undercuts upfront.
Silicone Mold Fabrication (48 Hours)
Liquid platinum silicone is poured over your master pattern in a vacuum chamber, eliminating bubbles for flawless detail capture. Our molds:
- ⇒ Achieve 30+ shots (vs. industry-standard 20).
- ⇒ Support textures: SPI gloss, VDI grit, custom EDM.
- ⇒ Cure 2× faster via controlled thermal acceleration.
Vacuum Casting & Intelligent Finishing
Under vacuum, we inject engineering-grade urethanes (ABS-like, PC-like, TPU) into molds. After curing:
- ⇒ Zero-Defect Guarantee: 100% inspection via CMM & visual QA.
- ⇒ Scalable Output: Produce 15–20 parts/mold/day (50% faster than competitors).
- ⇒ Smart Post-Processing: CNC trimming, painting, or pad printing—track progress in real-time via your dashboard.
Urethane Casting: From Prototype to Market
Accelerate Your Product Journey
Accelerate your product journey with end-to-end vacuum casting solutions engineered for speed-to-market—no tooling investment required.
Concept Validation (1–5 Days)
➤ Turn napkin sketches into tangible proofs faster than 3D printing
➤ Instant DFM Feedback: AI-powered analysis within 1 hour of CAD upload
➤ Same-Day Master Patterns: SLA/DLP printed at ±0.05mm accuracy
➤ Zero Tooling Costs: Ideal for verifying form, ergonomics, and aesthetics
Functional Prototyping (5 Days | 1–50 Units)
➤ Test like it’s production — without production delays
➤ 48-Hour Silicone Molds: Platinum-cure for 30+ high-fidelity shots
➤ True Material Mimicry: ABS-like, PC-like, or TPU resins with >95% property match
➤ Critical Testing Ready: Validate snap-fits, seals, and impact resistance
Bridge Production (5–7 Days | 50–500 Units)
➤ Launch products before injection molds are cut
➤ Batch Consistency: Automated vacuum casting for ±0.10mm tolerances
➤ Scalable Capacity: Produce 200+ parts/week—no volume surcharges
➤ End-Use Compliance: Medical (USP VI), flame-retardant (UL94 V-0), optical clarity
Low-Volume Manufacturing (Ongoing | 500+ Units/Yr)
➤ Your agile alternative to mass production
➤ Perpetual Mold Life: Mold refurbishment for 100+ additional shots
➤ Cost-Optimized Runs: 40% lower per-part cost vs. competitors at 100-unit batches
➤ Just-in-Time Delivery: Kanban-supported replenishment
Our Solution - One partner. No tooling. No minimums. No delays.
Speed Dominance
Volume Flexibility
Material Superiority
Risk-Free Scaling
Urethane Casting Services and Capabilities
Production-ready urethane cast parts in just 5 days—accelerating your product development from functional prototyping to low-volume end-use production (10-500+ units). Operating from ISO 9001:2015 and ISO 13485:2016 certified facilities, we guarantee cost efficiency and on-time delivery with industry-leading speed: 48-hour mold fabrication and same-day resin casting under vacuum ensure ±0.10mm tolerances while slashing traditional lead times by 40%. Choose from the broadest range of engineering-grade polyurethanes—including ABS-like, PC-like, TPU, FDA-compliant, and medical-grade resins—with custom finishes for automotive, aerospace, medical, and consumer applications. Zero minimum order quantities and real-time production tracking provide unmatched flexibility, making us the smart alternative to injection molding for batches under 500 parts.
Technical Capabilities & Specifications
| Parameter | Specification | Detail |
|---|---|---|
| Tolerance | ±0.15mm (local), ±0.10mm (small holes) | ISO-2768-C compliant |
| Max Part Size | 2.3 × 1.3 × 0.6 meters | Accommodates large components |
| Daily Capacity | 200 pieces | Scalable for batch production |
| Surface Roughness | SPI A1 (0.012–0.025μm Ra) to VDI textures | Glossy, matte, or technical finishes |
| Lead Time | 5 days (simple parts) | Includes mold creation, casting, finishing |
3D Printing vs. Vacuum Casting vs. Injection Molding
| Parameter | 3D Printing | Vacuum Casting | Injection Molding |
|---|---|---|---|
| Production Volume | 1–100 units | 10–200 units | 1,000+ units |
| Tooling Cost | $0 | $500–$3,000 | $5,000–$50,000+ |
| Per-Unit Cost | High | Moderate | Low (at scale) |
| Lead Time | 1–3 days | 5–15 days | 4–12 weeks |
| Material Options | PLA, ABS, resins, nylon | Polyurethane (ABS/PC-like) | ABS, PP, PC, elastomers, etc. |
| Tolerance & Precision | ±0.1–0.5mm | ±0.15mm | ±0.1–0.2mm |
| Surface Finish | Layered, rough | Near-production quality | Production-grade finish |
| Design Flexibility | High (complex geometries) | Moderate (some undercuts) | Restricted (draft angles needed) |
| Mold/Part Durability | N/A (direct print) | 15–50 uses | 100,000+ cycles |
| Material Waste | Moderate | Low | Negligible |
| Best For | Prototypes, jigs, 1-offs | Functional prototypes, bridge runs | Mass production |
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ABS likeCasted ABS-like polyurethanes closely mimic the look and feel of injection-molded ABS. Ideal for high-quality prototypes or small production runs, offering excellent surface finish, detail, and customizable properties. Finishing Options
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Acrylic likeAcrylic-like polyurethane blends the clarity of acrylic with the durability of polyurethane. Offers UV stability, weather resistance, and is ideal for both decorative and functional applications. Finishing Options
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POM likePOM-like polyurethane mimics polyoxymethylene with superior wear resistance, dimensional stability, and chemical resistance. Suitable for precision parts like gears and bearings in industrial applications. Finishing Options
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Polypropylene likePolypropylene-like polyurethane is lightweight, chemical-resistant, and UV-stable, ideal for automotive and packaging. Offers high tensile strength and excellent flexibility. Finishing Options
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Medical-gradeDesigned for biocompatibility, medical-grade polyurethane is used in catheters, implants, and wound care. Offers bacterial resistance, high flexibility, and durability in healthcare environments. Finishing Options
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Polycarbonate likePolycarbonate-like polyurethane offers excellent impact resistance, optical clarity, and UV protection. Ideal for enclosures, lenses, and impact-resistant parts in consumer and industrial uses. Finishing Options
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Urethane Casting Applications
Automotive & Mobility
- Interior Systems: UV-resistant dashboards, tactile buttons, vent grilles
- Underhood: Heat-shielded sensor housings (180°C EP-430 resin)
- Validation: Overmolded gaskets, snap-fit assemblies for crash testing
Medical & Life Sciences
- Biocompatible Devices: USP Class VI surgical tools, fluid connectors
- Diagnostic Gear: Fog-resistant transparent housings for imaging
- Wearables: Skin-safe wearable trial batches (50 units in 7 days)
Industrial & Robotics
- Robotics: Oil-resistant gripper pads, impact-absorbing joints
- Machinery: Chemical-resistant guards, custom tooling fixtures
- Energy: Dielectric bushings, arc-resistant switch covers
Electronics & IoT
- Enclosures: IP67-rated cases with living hinges, snap fits
- Connectors: Overmolded USB ports, heat-free insert molding
- Consumer Tech: Silky-touch grips, optically clear display covers
Aerospace & Defense
- Cabin Interiors: Flame-retardant (UL94 V-0) seat components, ducting
- Avionics: EMI/RFI-shielded enclosures, vibration-dampened mounts
- Drones: Lightweight propeller housings (0.8g/cm³ foamed resins)
Zero-Compromise Quality Assurance
Certified Precision for Critical Parts
As an ISO 9001:2015 certified provider, we enforce rigorous quality protocols across our global manufacturer network. Every vacuum-cast part undergoes triple-validated inspections – blending speed with uncompromised accuracy.
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Dimensional & Geometric Verification |
Metrology Suite: In-house CMM (±0.003mm), optical comparators, and laser scanners Real-Time Reporting: Deviation maps synced to your dashboard Critical Checks: • Tolerances to ±0.10mm (50% tighter than industry average) • Wall thickness uniformity, hole positions, and GD&T alignment |
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Surface & Aesthetic Integrity |
Flaw Screening: Bubbles, sink marks, and flow lines under UV/white light Defect Detection: 10× magnified visual inspections + SPI/VDI roughness testers Standards Compliance: • SPI A1–VDI 3400 finishes (glossy/matte/textured) • Pantone color matching (ΔE < 1.5) |
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Material & Performance Validation |
Functional Validation: Snap-fit, leak, and impact tests for end-use readiness Resin Certification: Batch-tested tensile strength, hardness (Shore A/D), and heat deflection Compliance Testing: • Biocompatibility (USP VI/ISO 10993) for medical parts • Flame Resistance (UL94 V-0) for automotive/aerospace • Adhesion Cross-Cut Testing (ASTM D3359) for coatings/platings |
100% Quality Guarantee:
"We re-cast or refund any part failing inspection – with expedited 3-day turnaround."
“No shortcuts. No surprises. Just production-grade parts – on time, every time.”
Why Choose Our Urethane Casting Services?
Partner with us for production-ready parts in just 5 days—combining the tight tolerances (±0.10mm) and material
versatility of urethane casting with the agility only an on-demand manufacturing leader delivers. Unlike platforms that
outsource to unvetted workshops, our ISO 9001:2015 and ISO 13485-certified manufacturer network guarantees consistent
quality at any scale—from 1 prototype to 500+ end-use parts—with no minimum order sizes. We simplify complexity: submit
your CAD via our intuitive dashboard for instant DFM feedback, real-time order tracking, and seamless scaling, all
backed by a 100% quality guarantee that includes first-article inspection reports and material certifications.
While competitors limit flexibility, we offer industry-leading speed (48-hour mold fabrication, same-day casting) and
50+ engineering-grade resins—from medical-compliant to aerospace-grade urethanes. Our platform eliminates friction:
manage projects 24/7 with batch replication, automated quotes, and dedicated engineer support. Choose confidence over
compromise: we absorb the risk with on-time delivery, zero tooling investments, and ISO-certified precision that turns
concepts into market-ready parts faster.
The Platform Advantage - Unified Oversight for Precision Manufacturing
Our integrated dashboard delivers end-to-end project command—streamlining workflows while ensuring transparency at every stage. Experience seamless coordination from initial request to final delivery, all within a single secure interface.
Submit & Configure with Precision
| RFQ Initiation |
Upload CAD files (STEP, IGES, SLDPRT) and drawings Specify requirements: materials, tolerances, finishes, inspection protocols Request custom documentation: material certs, CMM reports, customs forms |
| Real-Time Quoting |
Receive instant DFM analysis with cost drivers flagged Adjust configurations (e.g., material substitutions) to optimize pricing |
Order Execution & Oversight
| Document Management |
Submit customs declarations, commercial invoices, and HS codes Upload purchase orders or approve terms for payment Access digital invoices with tax/line-item breakdowns |
| Production Intelligence |
Track progress and updates View Shop floor photos/videos Access Inspection reports, quality documents and Material certifications Monitor shipping status with carrier integrations |
Proactive Collaboration & Support
| Engineer Engagement |
Send technical queries and status enquiries to our engineers via encrypted chat Receive resolution timelines for technical queries |
| Quality Assurance Hub |
Access pre-shipment documentation: First-article inspection reports, dimensional reports and quality documents Approve/reject deliverables via annotated media |
| Post-Delivery Excellence |
Initiate reorders with one-click cloning Log support tickets for non-conformances Archive project history (drawings, certs, comms) for audits |
Industries specialized
Aerospace
Automotive
Consumer Products
Medical
Frequently Asked Questions
Vacuum casting (urethane casting) is a low-volume manufacturing process that uses silicone molds to produce high-fidelity plastic or rubber parts (typically 10–500+ units). It’s ideal when you need:
We streamline workflows via:
Beyond standard ABS/PC-like resins, we provide:
FDA-compliant/medical-grade resins (USP Class VI) for surgical tools or food-contact items
Optical-clear PMMA (92% light transmission) for lenses or displays
Yes – with no minimum order requirements:
Our ISO 9001:2015 & ISO 13485-certified network guarantees:
We support applications across:
Here’s a simplified breakdown:
| Factor | 3D Printing | Vacuum Casting (Us) | Injection Molding |
|---|---|---|---|
| Tooling Cost | $0 | $350–$1,500 | $5,000–$50,000+ |
| Ideal Volume | 1–20 | 1–500+ | 1,000+ |
| Lead Time | 1–3 days | 5 days | 4–12 weeks |
| Surface Finish | Layer lines (needs post-work) | Near-production (SPI A1-VDI) | Production-grade |
| Per-Part Cost | $$$ (1–10 units) | $$ (20–100 units) | $ (1,000+ units) |
Our dashboard enables: