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upamfva · 28.06.23 - 08:18

Overview of Vacuum Casting

Vacuum casting is a casting process that uses a vacuum to draw a liquid material into a silicone mold to create complex components. Elastomers such as plastic resins and liquid silicone rubber are used as liquid materials in vacuum casting.Get more news about Vacuum Casting Part,you can vist our website!

Because polyurethane resin, a type of elastomer, is used as the casting material, vacuum casting is also known as polyurethane casting or urethane casting. Because the production cost of vacuum casting is lower, it is a more cost-effective alternative to injection molding for making plastic components.

Vacuum casting is an excellent manufacturing method for batch production and other low-volume jobs. Vacuum casting is widely used in the production of consumer goods as well as industrial electronics.

What materials are used in vacuum casting?
Casting polymers are available in a variety of hardness and surface texture combinations. Depending on your application, you can also create parts that are fully opaque, translucent, or completely transparent.

Polyurethane is the most commonly used casting material in this process. Polyurethanes have a variety of properties, including structural rigidity, elasticity, flexibility, shock and temperature resistance, and so on. As a result, different polyurethanes can be used depending on the type of product being manufactured.
What is the Process of Vacuum Casting?
Vacuum casting is similar to injection molding in that the cast material is injected into molds to produce products. The types of molds used distinguish vacuum casting from injection molding.

Molds for injection molding are made of aluminum, steel, and other materials. Silicone molds, on the other hand, are used in vacuum casting. Because silicone is less expensive and has a longer lifespan, this significantly reduces the cost of the mold. Below are the typical steps of vacuum casting.

#1 Design of the component

The first step in making any vacuum cast component is to create a 3D model of the component in question. The model is created using the same design guidelines as injection molding molds.

Before creating the 3D model, proper calculations must be performed. Deformities in the model can have an impact on the finished product after casting. As a result, it is critical to adhere to design guidelines and make necessary adjustments to calculations.

#2 Creating a mold master pattern

The mold’s master pattern is created using 3D rendering. The master pattern is the primary mold used to create the silicone molds that will be used for casting. It is a prototype for silicone molds made of high-durability materials such as metals or other plastics.

Previously, master patterns were created using CNC or hand tools, but today, processes such as 3D printing, stereolithography, and other such processes are used to create master patterns that are more cost-effective and precise.

Because the silicone molds are copies of the master pattern, any deformation on the master pattern will cause the silicone molds to deform. As a result, a high level of precision is required when creating the master pattern.

#3 Producing silicone molds

The next step is to create silicone molds after creating the master pattern. The master pattern and a casting box are used to create silicone molds directly.

Inside the casting box, the master pattern is suspended. Cores and inserts are inserted into the master pattern. Along with the core, the casing box contains casting gates and risers for pouring molten silicone and removing the final mold.

Around the master pattern, hot, molten silicone is poured into the casting box. It flows inside the master pattern, filling all of the prototype mold’s crevices. For about 8-16 hours, the molten silicone is allowed to cure inside the casting box, which is kept at 40°C.

When the silicone has solidified and the curing process has been completed, the risers are removed and the silicone mold is removed from the casting box. To keep casting deformations to a minimum, the entire process is carried out under a vacuum.

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