Urethane Casting Services
Production Quality in 10 Days
The perfect bridge between prototyping and mass production. DFocus PROTOTYPE uses silicone molds to produce high-quality plastic parts that mimic injection molding properties at a fraction of the cost.
- Production-Grade Surface Finish
- Wide Range of Materials (Rigid, Rubber, Clear)
- Cost-Effective for Low Volumes (10-50 pcs)
10-day turnaround. 15-25 parts per mold.
The Vacuum Casting Process
A fast and economical way to produce small runs of plastic parts without expensive steel tooling.
Master Pattern
We CNC machine or 3D print a high-resolution master. This pattern is polished to a mirror finish to ensure the final parts are perfect.
Silicone Molding
Liquid silicone is poured around the master. Once cured, the mold is carefully cut open and the master removed, leaving a precision cavity.
Vacuum Casting
Polyurethane resin is injected under vacuum. The parts are cured in an oven and removed. We repeat this for up to 20 parts per mold.
Materials & Applications
Material Simulants
- ABS-like: General purpose, good strength.
- PP-like: Flexible, snap-fit capable.
- PC-like: Clear, transparent, high impact.
- Rubber-like: Elastomers (Shore A 30-90).
Ideal Applications
- Marketing samples & Trade show models
- Functional testing & Engineering verification
- Pre-production bridge manufacturing
- Low-volume housing and casings
- Overmolded buttons and grips
Key Specifications
- Mold Life: 15-25 parts typical
- Tolerance: ±0.3% (min ±0.15mm)
- Max Size: 2000mm x 1000mm x 800mm
- Wall Thickness: Min 0.75mm recommended
Why Choose Vacuum Casting?
Ideal for when you need 10-50 parts with production-like quality but haven't locked the design for steel tooling.
- Low Initial CostSilicone molds are significantly cheaper and faster to make than aluminum or steel molds.
- Surface FinishReplicates the master pattern's texture perfectly, including high gloss, matte, or sandblasted finishes.
- SpeedFirst parts in hand within 10-14 days.
Alternatives
3D Printing (SLA/SLS)
Better for quantities < 10. No mold cost, but surface finish and material properties may be inferior to casting.
Rapid Tooling (Injection Molding)
Better for quantities > 100. Higher upfront cost but lower unit price and real thermoplastic materials.
Urethane Casting FAQ
How many parts can I get from one mold?
A typical silicone mold lasts for about 15 to 25 shots before the surface quality begins to degrade. For larger orders (e.g., 50 parts), we will create multiple molds from the same master pattern.
Are the material properties the same as production plastics?
Urethane resins simulate the properties of production plastics (like ABS or PC) very closely in terms of hardness, flexibility, and appearance, but they are not identical. They usually have lower heat deflection temperatures and UV resistance than thermoplastics.
Can you cast clear parts?
Yes. We use clear urethane resins (like PMMA-simulant) and polish the master pattern to a high gloss to achieve water-clear transparency for lenses and light pipes.
Production Quality Prototypes
Get 10-100 high-fidelity plastic parts in just 2 weeks. Upload your CAD file to get started.
Get Casting Quote