Vacuum Casting, Production Quality Small Batches In Polyurethane
When 3D printing is not cosmetic enough and injection moulding is not justified yet, vacuum casting delivers 1 to 50 polyurethane parts that look and feel like injection moulded production. Voxelcore India casts cosmetic grade prototypes, multi material over moulds and rubber elastomer parts from our own facility.
Why Vacuum Casting Beats Both Prototyping And Tooling
When you need 5 to 50 cosmetic grade parts and you need them next week.
1 To 50 Identical Parts
The fastest route to a small batch of polyurethane parts that look and feel like genuine injection moulded production.
Production Like Polymers
Polyurethanes that mimic ABS, PP, rubber and clear PC, across a full range of Shore hardness and optical clarity.
No Tooling Investment
Silicone moulds cost a fraction of aluminium tooling and are ready in 7 to 10 days from a master pattern.
Over Mould And Insert Capable
Multi material parts, soft touch grips, insert cast threaded bushings and embedded electronics are all possible.
Cosmetic Grade Finish
Mould replicated SLA pattern surfaces deliver a cosmetic finish equivalent to a T1 injection moulded part.
GST Compliant Invoicing
Clear, itemised invoicing on every job, GST compliant throughout, with tracked dispatch anywhere in India.
From CAD To Demoulded Polyurethane Part
A clear, engineer reviewed process from a single master pattern through to finished, cosmetic grade parts.
Master Pattern
We print an SLA master to your CAD with a crisp surface finish and tight tolerances. This becomes the mould pattern.
Silicone Mould
The master is suspended in a frame and platinum cure silicone is poured around it under vacuum. The cured mould is split and the master removed.
Vacuum Cast
Two part polyurethane is mixed and degassed, poured into the silicone mould under vacuum, then oven cured.
Demould, Trim, Finish
Parts are demoulded, gates trimmed and finished, with paint, priming, clear coat or assembly as required.
Silicone Moulding With Cosmetic Grade Results
Vacuum casting is built around an SLA master pattern that sets the surface finish and dimensional accuracy for everything that follows. The pattern is encased in platinum cure silicone under vacuum to capture every detail, then two part polyurethane is poured into the cured silicone mould, again under vacuum to eliminate bubbles, and oven cured. What comes out is a cosmetic grade part in a production like polymer, ready for paint, pad printing or assembly.
An SLA master pattern with a crisp surface finish and tight tolerances
Platinum cure silicone moulds good for roughly 15 to 25 parts per mould
Rigid ABS like and PP like, flexible Shore 30A to 80A, clear and flame retardant polyurethanes
Multi shot over moulding for soft touch grips on a rigid body
Insert cast brass bushings, magnets and embedded electronics
In house paint, pad print, clear coat and assembly finishing
Polyurethanes For Every Prototype Need
From a rigid ABS like consumer prototype to a Shore 30A rubber gasket or an optically clear lens prototype.
ABS Like Polyurethane
Tough and paintable, it looks and behaves like injection moulded ABS. The default choice for consumer prototypes.
PP Like Polyurethane
A polypropylene like polymer for caps, closures and parts that need a hint of flex and chemical resistance.
Clear Polyurethane
Optically clear for prototype lenses, light guides and transparent housings.
Rubber PU, Shore 30A To 80A
A full range of rubber like polyurethanes for over moulded grips, seals, gaskets and elastomeric components.
High Temperature Polyurethane
Rated to roughly 120 degrees Celsius for under bonnet and other heated environment prototypes.
Flame Retardant Polyurethane
A UL94 V0 rated polymer for electrical housing prototypes that need to pass a flammability spec at trial stage.
Where Vacuum Casting Earns Its Keep
Anywhere you need 5 to 50 cosmetic grade parts faster and cheaper than any other process can deliver.
Trade Show Samples
10 to 50 cosmetic grade product samples for trade shows, sales demonstrations and investor presentations.
Medical Trial Quantities
Small batch quantities of device housings for clinical trials, ahead of any bridge or production tooling decision.
Film And TV Props
Multiple identical prop copies in rubber or rigid polyurethane, typically 5 to 20 hero pieces with safety duplicates.
User Testing
Multiple physical samples for user testing sessions, ergonomic studies and focus groups before any tooling commitment.
Automotive Interior Trim
Multi colour, multi material interior trim prototypes with over moulded soft touch areas.
Design Verification
Final finish verification copies that show exactly what the part will look like, feel like and behave like in a user's hands.
Recent Vacuum Casting Work
Frequently Asked Questions
Usually 15 to 25 parts before the silicone starts losing dimensional accuracy and surface finish. For a larger batch we cast multiple moulds from the same SLA master, or move the project onto aluminium bridge tooling instead.
Typically within 0.3mm or 0.3 percent of the feature size, whichever is greater. Shrinkage is predictable and we compensate for it at the master pattern stage. Features that need tighter tolerances than that, around 0.1mm, are usually machined or threaded after casting.
Vacuum cast parts look and feel closer to real injection moulded production, with proper paint adhesion, no visible layer lines and consistent material properties across the batch. 3D printing is still faster for one to three parts, but vacuum casting takes over as the better option from roughly five to ten identical parts onward.
Yes. Multi shot vacuum casting can produce a rigid polyurethane body with a Shore 40A to 80A soft over moulded grip as a single demoulded part. Insert casting threaded brass bushings into the same part is also standard practice for us.
Yes. Polyurethane takes paint, primer, clear coat and pad printed graphics directly. A well prepared silicone mould gives a surface finish comparable to a cosmetic grade T1 injection moulded part straight off the tool.
The master pattern, silicone mould and first parts together typically take 10 to 15 working days from an approved CAD file. Repeat batches from the same mould come back in 3 to 5 days. An express turnaround can be arranged for a time critical trade show or launch.
Ready To Start Your Vacuum Casting Project?
Upload your file or send a quick brief. Most quotes come back within four working hours, with parts dispatched pan India from our production facility.