To ensure high-precision, bubble-free, and void-free components, we follow a standardized technical workflow. First, a high-quality master model (typically produced via high-accuracy CNC machining or SLA 3D printing) is prepared. Liquid silicone rubber is poured around the master inside a mold frame. Once the silicone cures at a controlled temperature, it is precisely split, and the master model is removed, leaving a highly accurate silicone cavity ready for casting production.
Optimized for Low-Volume Production Our engineers carefully design gas vents during the mold-making phase to guarantee flawless surface quality. This rapid vacuum casting prototyping method is ideal for small batches, with each silicone mold capable of producing 10 to 20 high-quality copies. It is the perfect solution for bridging the gap between prototyping and mass production.
Premium Finishing Services At Kaiao-RPRT, we provide comprehensive custom vacuum casting solutions tailored to your needs. We don’t just cast; we finish. Our post-processing services include polishing, silk screening, laser etching, and chrome plating. Whether for visual models or rigorous functional testing, we deliver vacuum cast parts that look and perform like end-use products.
Process steps:
1. Produce high-accuracy master model via CNC or SLA
2. Prepare and de-air the liquid silicone rubber
3. Pour silicone around the master under vacuum
4. Cure the silicone mold and carefully extract the master
5. Inject liquid polyurethane resin into the silicone cavity
6. Cure the resin in oven and demold the final part
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.
KAIAO operates large-capacity vacuum casting chambers capable of accommodating massive silicone molds up to 2.0m x 1.2m x 1.0m. This allows us to produce seamless, single-piece low-volume runs of oversized components such as automotive instrument panels, bumpers, door inner trims, and medical device enclosures, ensuring exact structural integrity without partition bonding.
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.
