Prototype-Grade Vacuum Casting Services
Vacuum Casting serves medical, aerospace, and R&D industries requiring low-volume precision. Key parts:
- Medical device prototypes
- Aerospace duct replicas
- Consumer product pre-production samples
- Automotive lighting prototypes
- Robotics component mockups
- Architectural model fittings
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Service
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Standard Vacuum CastingCreates precise prototypes (±0.2mm) with silicone molds and polyurethane resins. Produces 10-50 pieces/batch in 24-48hr. Ideal for medical/consumer goods testing and pre-production. -
Advanced Vacuum CastingMerges vacuum + centrifugal force for injection-molding quality (Ra0.8μm). Uses engineering resins (ABS/PP-like) for automotive parts. Reaches 95% density with 72hr mold life. -
Vacuum Casting for Rapid PrototypingWorldsoaring achieves ±0.15mm accuracy with silicone molds, delivering functional prototypes in 3-5 days using polyurethane systems. -
Vacuum Casting for Mass ManufacturingWorldsoaring guarantees mass production with tight tolerances, full QA, and supply chain integration for cost-effective precision parts.
Our High-Fidelity Vacuum Casting Parts
Producing 20-500 urethane prototypes with 0.1mm feature replication from silicone molds. Ideal for functional testing of ABS/PP-like parts, with color matching and texture finishing options within 3-5 working days.
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10+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
210+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest -
310+ Years of CNC Machining ServicesTight Tolerance of 0.005mmInstant Quote As fast as 2 Hours2 working days deliver time at fastest
Vacuum Casting Materials
Producing functional prototypes in PU resins mimicking ABS, PP or rubber (Shore 40D-80D). Color-matched urethanes with texture replication for consumer product validation within 0.2mm accuracy of production parts.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
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Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
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Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
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Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
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High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
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High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
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Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
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Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
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Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
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Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
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ABS (Acrylonitrile Butadiene Styrene)
Key Properties: High impact resistance, rigidity, excellent machinability, moderate chemical resistance.
Industries: Automotive (dashboards, trims), consumer electronics (housings), toys.
Advantages: Cost-effective, easy to mold, paintable.
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Key Properties: Optical clarity (>92% light transmission), UV resistance, weather resistance.
Industries: Signage, medical devices (incubators), automotive lighting (lenses).
Advantages: Superior to glass in shatter resistance; polished edges enhance aesthetics.
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Key Properties: Low friction, high stiffness, dimensional stability, fatigue resistance.
Industries: Precision gears, conveyor components, medical inhalers.
Advantages: Replaces metal in high-wear applications;
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Key Properties: High adhesion strength, chemical resistance, thermal stability.
Industries: Coatings, composite materials, electronics encapsulation.
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Bonds metals, plastics, and ceramics effectively.
Maintains performance under high heat (<200°C).
Customizable curing (heat, UV, catalysts).
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Key Properties: Wear resistance, high tensile strength, temperature resistance (-40°C to 120°C).
Industries: Automotive (bushings), textile machinery (gears), sports equipment.
Advantages: Cost-efficient alternative to PEEK; suitable for injection-molded wear parts.
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Key Properties: Flame retardant (UL94 V-0), high heat deflection (217°C), chemical resistance.
Industries: Aerospace (cabin interiors), medical (sterilizable trays).
Advantages: Meets stringent FAA/SFDA standards; replaces metal in lightweight designs.
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Key Properties: Lightweight, fatigue resistance, microwave-safe.
Industries: Automotive (battery cases), medical (syringes), packaging.
Advantages: Low-density material reduces shipping costs; weldable for tank fabrication.
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Key Properties: Barrier to CO2/O2, recyclable, food-safe.
Industries: Packaging (bottles), textiles (fibers), electronics (insulation).
Advantages: Low-cost alternative to polycarbonate for transparent applications
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Key Properties: Impact resistance (250x stronger than glass), transparency, heat resistance.
Industries: Safety goggles, bullet-resistant windows, LED light covers.
Advantages: Combines clarity with durability; ideal for injection-molded transparent parts.
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Key Properties: Chemical inertness, low moisture absorption, FDA-compliant.
Industries: Food processing (cutting boards), chemical tanks, marine components.
Advantages: UHMWPE excels in high-abrasion environments (conveyor liners).
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Key Properties: Flame retardant (self-extinguishing), weatherability.
Industries: Construction (pipes), cables (insulation), medical tubing.
Advantages: Cost-efficient; customizable with plasticizers for flexibility.
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High melt viscosity (300-350°C processing), moisture-sensitive (0.02% max), optical-grade clarity for LED lenses and medical device components.
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High mold temperature (60-80°C) reduces internal stress, low warpage, replaces glass in automotive taillights and cosmetic packaging.
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Crystallization-sensitive cooling (80-120°C mold), high dimensional stability, precision gears and fuel system valves.
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Moisture absorption (2.5-3.5%) requires post-molding annealing, self-lubricating bushings and automotive cable ties.
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Low melt strength (LDPE: 160-240°C), high flow rate for thin-wall containers and chemical-resistant pipeline fittings.
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Extreme processing temps (380-400°C), low shrinkage (0.1-0.3%), aerospace bushings and surgical sterilization trays.
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Fast crystallization (mold temp 60-80°C), glass-fiber reinforced connectors in automotive ECU housings.
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Low density (0.9g/cm³), living hinge capability, disposable syringes and automotive HVAC ducts.
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Non-melt flow (sintering required), ultra-low friction coatings for semiconductor seals and non-stick cookware linings.
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Vacuum Casting Tolerances and Standards
Worldsoaring offers a range of vacuum casting tolerances to meet your complex custom requirements. Depending on the master model and part geometry, we can achieve dimensional tolerances between 0.2 – 0.4 m. Below are the technical specifications for our custom vacuum casting services.
Vacuum Casting Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
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As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
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AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
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AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
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Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
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BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
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EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
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Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
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ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
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ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
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GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
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Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
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KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
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Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
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OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
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PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
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PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
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Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
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PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
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PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
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Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
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What is Vacuum Casting?How Does Vacuum Casting Work?
Vacuum casting is a precision manufacturing process that uses silicone molds and polyurethane resins to produce high-quality prototypes or small-batch parts under vacuum conditions. It bridges prototyping and mass production.
A master model (3D printed/CNC machined) is placed in a casting box Liquid silicone is poured and cured around it to create the mold.
The mold is cut open and the master removed.Resin is poured into the mold under vacuum to eliminate bubbles.Cured parts are demolded (each mold lasts 15-25 casts)
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CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Vacuum Casting Projects
FAQs
Is vacuum casting cheaper than injection molding?
For quantities below 500 units, vacuum casting typically offers 40-70% cost savings by eliminating steel tooling (saving 5,000−5,000−50,000). Injection
molding becomes economical at 1,000+ units due to per-part cost reduction below $2.50. Material selection (urethane vs. engineering resins)
further impacts break-even points.
How long does vacuum casting lead take?
Standard vacuum casting projects require 5-15 working days, depending on part complexity (0.5-5mm wall thickness), quantity (1-50 pieces per
mold), and post-processing needs (painting, assembly). Rush services can reduce lead times to 72 hours for simple geometries.
Why use vacuum casting?
Vacuum casting delivers superior value for rapid prototyping and low-volume production (1-500 units), offering exceptional detail reproduction with
surface finishes up to SPI A2 standard. This process eliminates expensive tooling while maintaining injection-molding-like quality at 30-60% lower
costs for small batches.
