Vacuum Casting Services
真空注型（ポリウレタン注型）は非常にポピュラーな技術であり、小ロット生産レベルの品質である硬質プラスチック、ゴム、シリコン部品を制作します。
- ISO 9001 & ISO 13485 認定書
- 7日間内に1～50個以上納品
- 24/7技術サポート
- 材料範囲広い
真空注型（ポリウレタン注型またはポリウレタン注型）
真空注型は射出成形に似ている製造プロセスであり、ポリウレタン樹脂は2つのシリコン金型のキャビティに注型されます。真空注型により、生産レベルの品質である硬質プラスチック、ゴム、シリコン部品を製造します。
注：真空注型はアメリカや欧米では、ポリウレタン注型やポリウレタン注型とも呼ばれている。本文では、この用語を両方とも利用して紹介します。
真空注型とは？
ポリウレタン注型は、キャビティの周りにシリコン金型を注型することによりキャビティを複製するプロセスである。プログラムによって、金型は2つに切断されて、メイン型を除去した後、ゲートと換気システムを追加します。メーカはポリウレタン系樹脂をキャビティに注入して、泡発生を防止するため、真空状態で硬化します。最後は元のオブジェクトの高精度コピー品になります。ポリウレタン注型プロセスは、真空状態で行われるため、表面テクスチャが滑らかで傷のと気泡なし高品質のプラスチック部品を製造することができます。
真空注型作業フロー
ポリウレタン真空注型品の生産は一般的に3つのステップに分けられる：先にマスタモデルを作って、次に金型を作り、最後に注型部品を作る。
ステップ1.マスターを作製する
It is worth noting that the model needs to be able to withstand heating at 40°C.
ステップ2。シリコン金型製造
- マスタモデルの周囲の平坦な場所にテープを置いて、後で金型を切断しやすいようにして、この位置も最終的なシリカゲル金型の分裂面になります。
- 注型箱にマスタモデルを掛け、プラスチック棒を配置してゲートと換気口を設定します。
- 液体シリコンをマスタモデルの周囲に注入して、すべての空気を除去し、マスタモデルに気泡がないように真空室を形成する。次に、液体材料をオーブンに入れて、40℃で硬化させる、金型の体積によって、通常8〜16時間かかります。
- シリコーンゴムが硬化した後、金型ケースを切開し、シリコーンゴムからマスタモデルを取り出す。金型を切開して母型を取り出した後、元の形状と全く同じキャビティが残ります。
ステップ3.真空注型プロセス
- 最初にシリコン型をオーブンに入れ、60 ~ 70℃まで予熱して、型合わせ前に適切な離型剤を選んで、粘着性と表面欠陥が発生したないように正しく使用することが非常に重要であります。
- ウレタン樹脂を使用する前に40°C程度に予熱して準備して、二成分注型樹脂を正確な割合で混合した後、真空条件で50〜60秒間完全に攪拌して、脱泡して、気泡などが発生しないようにする。
- 自動制御によって、樹脂を真空チャンバ内の金型に入れて、オーブンで再度硬化する。平均硬化時間：小さい部品は1〜3Ｈ、大きい部品3〜6Ｈかかります。
- 硬化後、シリコン金型から注型品を取り出す。
- 上記んお真空注型プロセスを繰り返します。
真空注型公差
真空注型物の公差は、マスタモデルの精度、幾何形状、および使用する注型材料の種類に依存します。一般に、収縮率は0.15%と予想されます。
信頼できる真空注型メーカ
真空注型ではAN-Prototypeが選べれる理由
中国の先進な真空注型メーカーとして、AN-Prototypeは高品質プラスチック部品は低コストで製造する提案を提供しています。ポリウレタン注型方法により、お客様高価な初期投資を回避でき、高品質のプロトタイプと小ロット生産部品を作成用の完全なソリューションを提供しています。
低コスト
ポリウレタン注型品は、安価な金型から作られており、高価で時間かかる金型に投資する必要はなくて、高品質の原型と小ロット部品を製造する用の経済的で効率的な方法です。
Fast Delivery
When you choose vacuum casting services, up to 50 functional polyurethane cast plastic parts can be produced in 7 to 15 days. Wide selection of materials
Complex Geometry Support
Vacuum casting provides end-use parts with high precision and fine detail of production-grade quality.The use of high-quality elastomer materials ensures the manufacture of vacuum-cast plastic parts with complex structures. Provide detailed design support.
Material and Finish Selection
Cast resin materials range from soft and flexible to rigid, impact-resistant, as well as colored and transparent, and support a wide range of surface treatment options to bring your products to life.Urethane casting can provide better surface textures than CNC prototyping or 3D printing.
Consistent Quality
AN-Prototype is proud to be ISO 9001&ISO13485 certified, ensuring our products and services meet international quality standards. We provide manufacturing analysis and quality control to deliver medical plastic parts to the highest standards.
Professional Vacuum Casting Expert
Get reliable custom vacuum casting services from skilled and experienced AN-Prototype experts. AN-Prototype invests in the best talent in the industry and has the ability to provide expertise in manufacturing, material selection, surface treatment and more.
Polyurethane Vacuum Casting Services
Trustworthy Polyurethane Vacuum Casting Service Rrovider
Vacuum Casting Material
AN-Prototype offers a variety of polyurethane materials to suit your application, including Hei-Cast from Japan and Axson from France. Materials with certain properties are similar to engineering production plastics, such as ABS, PMMA, PC, PP, PA, etc. Parts come in a variety of colors, from transparent, translucent to colorful, and from soft rubber to hard plastic. Various materials include impact resistant, high temperature (120°C) or flame resistant (UL94-V0), glass filled resins and silicones of varying hardness.
ABS-Like
ABS-Like is a thermoplastic, a versatile polyurethane plastic resin that is hard, rigid and impact-resistant, making it an ideal material choice for the manufacture of various parts.
Price: $$ (relatively inexpensive).
Color: Fits All Colors; Exact Pantone Matching Available
Hardness: Shore D 78-82
Typical Application: Enclosures
Acrylic-Like
Acrylic-Like hard, clear polyurethane resin, is an alternative to acrylic. It is hard, has medium to high strength and good transparency, suitable for transparent parts.
Price: $$
Color: transparent
Hardness: Shore D 87
Application: transparent components and parts
Polypropylene-Like
Polypropylene-Like is a tough, ductile and abrasion-resistant polyurethane material with low cost and polypropylene-like ductility.
Price: $$
Color: Black or Natural only
Hardness: Shore D 65-75
Application: Medical Housing
Polycarbonate-Like
Polycarbonate-Like is a rigid, high-impact, transparent material that is versatile and relatively easy to machine and finish, and is an alternative to polycarbonate.
Price: $$
Color: transparent and various colors
Hardness: Shore D 82-86
Application: sun visor、goggles
PA-like
PX223 is a PA-like material used in silicone molds to produce highly durable and versatile parts that perform similarly to nylon parts.
Price: $$
Color: black, tan
Hardness: Shore D 80-85
Application: Shell
PC-like
PX520 realizes prototype parts and models with mechanical properties similar to real PC material by casting in silicone molds.
Price: $$$
Color: white, transparent
Hardness: Shore D 80
PP-Like
UP 5690 has similar mechanical properties to genuine PP and HDPE materials. It is easy to process, has high impact resistance and good flexibility.
Price: $$$
Colors: White, Black
Hardness: Shore D 80
Application: bumper, equipment box
Glass-Filled Nylon-Like
Glass-Filled Nylon-Like is a stiff, USP Class VI, high-performance urethane with high impact strength and a HDT of 190°F (88°C).
Price: $$$
Colors: White
Hardness: Shore D 85
Application: Hard Case
Elastomer
Polyurethane plastic resin, simulating TPU, TPE, silicone rubber and other rubber materials.
Price: $$
Colors: All colors and exact Pantone color matching
Hardness: Shore A 20 to 90
Applications: Wearables, Overmolding, Gaskets
Cast Silicone Material
Silicone is not only a good material for casting tools, but it is also an excellent component material. Silicone is durable, resilient, tear-resistant, inert, easy to clean, and resistant to high temperatures. Silicone rubbers are available in ultra-soft durometers as low as Shore A 10 and as medium-hard rubbers in the Shore A 60 range. Silicone castings are ideal for medical devices, surgical models, soft touch enclosures, and more.
- Shore A 10 (TC-5005 or equiv.)
- Shore A 20-30 (TC-5130 or equiv.)
- Shore A 30-40 (TC-5140 or equiv.)
- Shore A 40-50 (TC-5150 or equiv.)
- Shore A 50-60 (Smooth‑Sil™ 960 or equiv.)
Technical Guide for Vacuum Casting
Standard Precision
The standard tolerance is ±0.15mm/100mm, and the highest precision can reach ±0.05mm.
Maximum Vacuum Casting Part
The vacuum equipment can accommodate mold specifications up to 2.0M*1.2M*1.0M.
Minimum Wall Thickness Part
The minimum wall thickness is 0.5mm, and the best setting is 1.5mm to 2.5mm to ensure the tolerance of the parts.
Lifespan of Silicone Mold
Typical quantity is 20-25 servings per mold. If the plastic part requires high quality, such as a complex structure, generally only 10 or even 15 copies can be produced in one mold.
Standard Delivery Time
Depending on the complexity of the mold and the number of parts required, typically up to 50 plastic parts can be made in 7 to 10 days.
Surface Textures and Other Options
Vacuum molding is similar to injection molding, and the surface of the part can be colored, textured, painted, coated, clear polished, embedded and overmolded.
Vacuum Casting Application
Vacuum casting is a method used to manufacture low-volume products that require near-production-grade quality. The process of polyurethane casting creates highly detailed plastic parts that are virtually indistinguishable from the final product. Cast urethane parts are ideal when runs of 1 to 100 plastic parts are required in color, finish quality and toughness.
Urethane casting is also a perfect alternative to insert molding or overmolding for small batches, with a variety of material options. Urethane or silicone castings can bridge the production gap between 3D printed rapid prototyping and injection molding, balancing quality, cost and time. Polyurethane cast parts can be clear, colored, inserts. Since about 20-50 replicas can be produced from one master pattern, vacuum casting also allows developers to launch a first series of products for early market testing.
Custom medical devices: prosthetics, orthotics, hearing aids.
Automotive parts: dashboards, knobs, gauges, signs, hood ornaments, lighting lenses, intake manifolds.
Consumer electronics: enclosures, controllers, user interface panels, sensor integration.
Critical components and spare parts for robotics and industrial machinery.
Consumer Goods: Limited Edition Sunglasses, Pens, Phone Cases.
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