Step 3: volume production
The vacuum casting resin and pigment are mixed and poured into the silicone mold, where they are fully mixed and degassed in vacuum for 50-60 seconds during the automatic pouring process. Next, by eliminating air pockets inside the tool, vacuum technology allows gravity to do all the work of filling the mold. The parts are then transferred to the oven for curing. Curing time also depends on part size. When it hardens, the casting can be removed from the mold. Once the casting is complete, the sprue and risers can be removed, and the final process is to trim the edges of the raw material and apply additional sanding and polishing with grit sandpaper. The first machined part after completion must be inspected for quality. If the first piece is qualified, production can continue. This process can be repeated 20 to 30 times on average. Exceeding these times will cause the mold to gradually deform and affect the dimensional accuracy.
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Selecting a suitable vacuum casting material is essential for creating high-quality castings. In addition to money, you might waste time by making the wrong decision. This guide post will discuss the different materials used in this technology as well as their applications.
To help you choose, we have compiled a list of Xometry&#;s numerous available vacuum casting resins. Rubber and plastics (ABS, PC, PMMA, and PP) account for the most common materials.
ABS is commonly employed in vacuum casting. It offers a good balance of properties and is easy to process due to its low melt viscosity. It displays good toughness, rigidity, and impact strength.
ABS has good dimensional stability, meaning that parts made from it will not warp or distort over time. In addition, it exhibits excellent chemical resistance and can be used in various applications.
Vacuum casting, also called urethane casting or polyurethane casting, is a popular choice for manufacturing small batches of parts due to its relatively low cost and quick turnaround time. ABS is an ideal choice due to its combination of properties and easy processing.
PU is a common material because of its excellent abrasion resistance and wear resistance, making it useful in many different settings. It is durable and resistant to oil and chemicals, making it an excellent fit for industrial settings.
PU is a polyurethane elastomer with high tear strength and is resistant to abrasion. It is hydrolytically stable and has a low compression set. The primary use for this product is in vacuum casting. It has a transparent or light-yellow tint.
ABS PU has excellent strength, thermal stability, and abrasion resistance. Its primary use is in the production of high-strength components via vacuum casting. This product is a kind of resin that has already been partially oxidized. Crosslinking density is high, and it maintains its shape well.
PX100 is a common material for rapid prototyping because of its toughness, durability, and impact resistance. It&#;s made up of isocyanate and polyol, and once combined, it takes on a milky white appearance.
PX215 is an ABS and unreinforced polycarbonate blend. Strong durability and dimensional consistency are two of the material&#;s numerous benefits. It has been UV-stabilized for increased durability in adverse conditions. It is most often used in injection moulding and vacuum casting.
The polyol and UP-2 (ISOCYANATE) are required to be utilized with ABS UP. It has no inherent colour but takes on the colour of whichever polyol it is combined with, changing to colours of off-white (C/2), black (K/2) or pale beige (N/2).
Material Tensile strength (MPa) Elongation at break (%) Flexural modulus (MPa) Hardness (Shore D) PU, ABS-like 73 16 1.2 &#; 2 84 PU, ABS-like 68 15 2.2 85 PU, ABS-like 68 15 2.2 83 PX100, ABS-like 40 20 1.5 74 PX215, ABS-like 58.8 120 2.45 120 UP, ABS-like 84 13 2.1 81
Polycarbonate (PC) is a durable, lightweight plastic that has a wide range of applications. One of the most popular uses for PC is vacuum casting.
Vacuum casting is where molten plastic is injected into a mould under vacuum pressure. This produces vacuum cast parts with very accurate dimensions and a high degree of detail.
PC is ideal because it has excellent dimensional stability and can be easily moulded into complex shapes. In addition, PC parts are solid and durable, making them ideal for applications where strength and durability are required.
Polyol (A) and Isocyanate (B) are mixed at a ratio of 100 (A):250 (B) to create this polyurethane resin PU. The material can be demoulded in 1 hour and has high impact strength.
It has several good qualities that are comparable to those of thermoplastic polymers.
The UP resin has a viscosity of 200 &#; 300 MPa. The material is a combination of Polyol and Isocyanate.
This PX223HT urethane is often used in vacuum casting processes. It is only available in black and has no gradations of colour. Products manufactured with this material have excellent impact resistance and are simple to cast because of the material&#;s low viscosity.
Material Tensile strength (MPa) Elongation at break (%) Flexural modulus (MPa) Hardness (Shore D) PX223HT, PC-ABS-like 60 11 2.3 80 PX510, PC-like 40 20 1.5 80 UP, PC-like 59 &#; 69 15 &#; 16 2.1 &#; 2.2 81 PU, PC-like 70 10 1.6 85
PMMA, also known as acrylic, is a transparent plastic that is often used in vacuum casting. This material is strong and shatter-resistant, making it ideal for vacuum casting. In addition, it has a high degree of clarity, making it perfect for applications where transparency is desired.
The PXHT material is created by combining UPX POLYOL, UPX ISOCYANATE, and UPX-S POLYOL. It has a high viscosity of 500-650 MPa. This material can withstand temperatures up to 105°C.
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UPX is a transparent anti-UV urethane resin used primarily for casting in silicone moulds. Parts with wall thicknesses up to 50 mm can be made using this material. Isocyanate and polyols are combined to create this material. Additionally, it is resistant to UV radiation.
X522HT is a translucent urethane resin designed to produce high-end transparent items. It may be cast in a silicone mould using a vacuum casting process. It&#;s an excellent option for greenhouses since it allows for the passage of light and acts as an effective heat barrier.
Material Tensile strength (MPa) Elongation at break (%) Flexural modulus (MPa) Hardness (Shore D) PXHT, PMMA / Acrylic-like 65 &#; 70 15 &#; 20 2 &#; 2.2 83 UPX, PMMA / Acrylic-like 65 &#; 70 15 &#; 20 2 &#; 2.2 83 X522HT, PMMA / Acrylic-like 75 9 2.1 87
Polypropylene (PP) is a thermoplastic polymer used in various applications. It is distinguished from other plastics by its high heat and chemical damage resistance.
It is also very lightweight and durable, making it an ideal material for vacuum casting. When heated, PP expands and becomes malleable, making it easy to shape into any desired form. This makes PP an excellent choice for creating prototypes and complex parts with intricate designs.
Vacuum casting is a versatile manufacturing process that can produce small or large batches of high-quality parts with precise dimensional tolerances.
is made by combining Polyol with Isocyanate in a 1:2 ratio. It has a transparent black-and-white appearance. Because of its excellent elongation capabilities, this material is often utilized to create elastic parts.
PU, PP-like consists of three portions. In a ratio of (Polyol 1 + Polyol 2): Isocyanate, two polyols and one isocyanate are combined. This material is appropriate for producing large components and has a long service life.
UP Polyol, UP Isocyanate, and UP C are the three components used to create this material PP (UP). It&#;s a polyurethane resin that can be vacuum cast, and it&#;s often used to make components with PP/HDPE-like qualities. The product&#;s mechanical qualities will change based on the proportions of the various materials used to produce it.
Material Tensile strength (MPa) Elongation at break (%) Flexural modulus (MPa) Hardness (Shore D) , PP-like 34 72 0.9 76 PU, PP-like 50 35 1.6 85 UP, PP-like 25 &#; 35 50 &#; 90 0.6 &#; 1.3 75 &#; 83
Rubber is a versatile material used in various applications. It is often used in vacuum casting because it can be easily moulded into complex shapes and has a high degree of flexibility.
In addition, rubber is relatively inexpensive and can be reused multiple times. As a result, vacuum casting with rubber is an efficient and cost-effective way to create high-quality parts and products.
UPX is a polyurethane material made up of three different components specifically designed for vacuum casting. This product has a very high elongation and is easy to work with. The material&#;s mechanical characteristics are determined by the proportions of the three components combined.
T is a translucent polyurethane elastomer designed and developed for vacuum casting applications. The material has a pot life of around 5 minutes and 30 seconds. Despite its apparent transparency, the product&#;s overall mechanical qualities are determined by the proportions of its three components (1 polyol, 1 isocyanate, and 1 polyol).
Material Tensile strength (MPa) Elongation at break (%) Hardness (Shore A) UPX, Rubber-like 17 430 95 T, Rubber-like 10 &#; 40 300 60 &#; 80
Choosing an appropriate material is sometimes a lengthy procedure. Xometry is your one-stop shop for custom vacuum cast parts. The company provides an extensive selection of casting materials with varying mechanical qualities to accommodate all vacuum-cast projects.
Upload your files to the Xometry Instant Quoting Engine to get a quote in a matter of seconds, and pick different vacuum casting resins to see how they affect the cost.