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vacuum casting rapid prototyping

vacuum casting rapid prototyping

Vacuum casting rapid prototyping

In many cases, casting metal in the natural environment produces quality stuff, but in some instances metal makers have figured out how to achieve optimal cast components. By using a vacuum casting technology to evacuate air in an enclosed area, either to produce a mold, pour castings or melt metal with complex and difficult properties. Vacuum casting is an additive procession used in conjunction with a stereo lithographic model and a silicon form that allows us to produce polyurethane castings models quickly. 

How Does It Works

Firstly, we converted the papers or physical models to the 3D data; also, we are willing to help you to meet your needs according to different situations. Then our skilled engineers start to design the silicon molds by analyzing data. When the craft has been established, CNC machining and SLA are there to producing the mockups.

Craft Procession

A silicon form is placed into a vacuum chamber and is filled with polyurethane. During this process, the silicon mold stay in a constant heating chamber, and then warming up to  60-70℃and then deforming and solidification are executed in the next procedures.


The vacuum sucks out any air trapped inside the silicon form, making sure that there are no air bubbles in the manufacturing. Also, gas vents are digging during this procession. After that, our excellent teams will help you realize your customized requirements. Considering the complexity of the prototype, generally, each of a silicon form can produce 10 to 20 pieces.


KAIAO focus on every detail to provide the best services and perfect products to clients, so finishing making including: polishing, silk screening, laser etching, chrome plating and more. And this allows the production of high-quality, complex prototypes for numerous purposes such as functionality tests.

Material Selection

The variety of polyurethanes available is so great that almost any material used in the finished product can be imitated using this process. Products used to copy material: PU, imported PU, transparent PU, soft PU, ABS, PP, and PC. It is even possible to create transparent, strengthened, colored and rubber prototypes.


With our Vacuum Casting Machines, we can produce standard parts as well as shaped parts (such as bearing sleeves or stud bolts) and reproduce the prototypes with original color, texture and geometries from prototypes to components. These plastic castings will represent the mechanical properties of the production parts from a steel mold.  
At KAIAO we can produce parts to extremely fine levels of detail. Our aim is to satisfy any tool maker’s production tooling requirement.
Find more about vacuum casting information, free for contact us.

Molding Ofbig Size Parts

The maximum volume of our Vacuum Casting Machine is: (2.0m x 1.2 m x 1.0m).  KAIAO provides Low Volume Short Run Productions of instrument boards, door panels, as well as Automotive Interiors and Exteriors.  The Size Precision of parts is controlled to ±0.2mm positioning accuracy and the Locating Hole, ±0.4mm positioning accuracy of the mounting hole.  The parts can meet the durability requirements of a 10,000km Road Test.

Low Volume Pre-production Of Complex Designs

At KAIAO, innovation and creative efforts are always ongoing so that we can find better ways to improve our production processes.  We believe in implementing our successful Silicone Tooling techniques and Vacuum Casting methods which are recognized by our clients.

• Over Molding is an advanced process of casting around and/or through Cores that are inserted into the Cavities of Molds, resulting in the production of Individual parts made of multiple materials.  Typically, a soft PU Resin is cast around and/or through a hard PU Resin to produce one part with two different Durometers and Colors.  Additionally, transparent parts such as PMMA lenses can be cast directly into housings.  This process allows for Hand Held products and Electronic Devices to be manufactured to meet (Vibration Minimizing, Impact Resistant, and Water Resistant) Functional Requirements.

• Metal Part Inserting is a mechanical process where PU Resins are cast around and/or through Metal Parts that have been inserted into Mold Cavities to produce IN-MOLD ASSEMBLED PARTS.  Machined Metal Parts, Stamped Metal Parts, Cast Metal Parts, as well as Brass Inserts can all be Over Molded to improve the mechanical strength, durability, and usability of parts with Functional Requirements.

• Melt Molding is a special process where Cores are cast using Wax or Low Melt Temperature Alloys.  These Cores are then placed inside the Mold Cavities.  The Over Molded Parts are removed from the Molds with the Cores still inside.  The Cores are then melted out using a heat gun and/or hot water.  Through this process, complex radiator pipes and corrugated tubing can be custom manufactured.

• The Coloration of Cast Parts is a creative process where Colors are added directly into the PU Resins to make IN-MOLD COLORED PARTS.  To Achieve IN-MOLD Texture and Gloss, we apply 2K paint onto the surface of the Master Patterns, which is copied into the Silicone Tool, allowing for parts to be produced with minimal Post Production Finishing and are similar to Plastic Injection Molding.

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