Capabilities / Vacuum Casting Services

Urethane Casting | Vacuum Casting Services

Custom urethane parts from prototyping to small production runs. ±0.01mm tolerance. 6 days delivery.

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CNC Machining Parts

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±0.02mm

Tolerance

20+

Machines

6 Days

Samples Delivered

ISO

13485, 16949, 14001

FlagShip Urethane Casting Service

FlagShip’s urethane casting services support every stage from prototype testing, function validation and market testing phases. Operating from ISO-certified facilities and vetted manufacturing partners, we ensure you stay on sechedule and within budget. We cast urethane parts with tolerances down to ±0.10mm and lead times as short as 6 days. A variety of polyurethane and silicone materials, surface finishes, and color options are available for applications in automotive, electronics, and consumer products.

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FlagShip Vacuum Casting Capabilities

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Feature Description
Tolerance At FlagShip, replicated casts follow ISO-2768-CL standards. Local tolerances can reach ±0.15mm, and small holes can achieve up to ±0.10mm precision.
Color and Finishing Supports a wide range of colors, transparency levels, and surface finishes.
Maximum Part Size Up to 2.3 × 1.3 × 0.6 meters.
Daily Capacity Up to 200 pieces per day.
Lead Time Lead time varies based on part complexity and order volume. The full process includes prototype making, silicone mold creation, casting, and finishing. Simple single parts can ship in under 5 days, but larger batches may require more time depending on the project.

From Prototyping to Production

Moving from initial concepts to market-ready products, FlagShip’s vacuum casting services offer cost-effective solutions for your product development.

Concept Validation

Quickly turn early designs into real parts using 3D printing. Great for checking size, shapge, and surface finish before moving forward. No need for hard tooling at this stage.

Prototyping

Make 1 to 100 functional vacuum cast prototypes for testing fit, strength, and usability. Materials and tolerances are close to final production.

SLow Volume Production

Perfect for low-volume runs, product launches, or bridge production. Cast 20 to 200+ parts with consistent quality and quick turnaround—skip the wait for injection molds.

Mass Production

For larger production needs, we offer injection molding to create high-volume plastic parts with consistent quality and lower unit cost.
Vacuum Casting Overview Vacuum Casting Types and Profiles Materials Finishes Applications Advantages and Disadvantages
Vacuum Casting Overview Vacuum Casting Types and Profiles Materials Finishes Applications Advantages and Disadvantages


What is Vacuum Casting?

Vacuum casting is a precision manufacturing process used to create high-quality plastic or rubber parts in small to medium production runs. By utilizing a vacuum to draw liquid material into a silicone mold, this technique produces detailed, consistent components that closely replicate the original master pattern. Ideal for prototyping and low-volume production, vacuum casting offers a cost-effective alternative to injection molding, with faster turnaround times and exceptional surface finish capabilities. Common applications include automotive parts, medical devices, and consumer electronics components, where accuracy and aesthetic quality are critical.

Vacuum Casting With FlagShip

At FlagShip, our vacuum casting services combine advanced technology with expert craftsmanship to deliver superior results for your project. We specialize in producing complex parts with tight tolerances, using state-of-the-art vacuum casting equipment and high-grade materials. From rapid prototyping to bridge production, our process ensures:

  • Precise replication of intricate details (down to 0.1mm accuracy)
  • A wide range of material options, including polyurethanes, silicones, and rubber-like compounds
  • Custom finishes (painting, plating, texturing) to match your specifications
  • Fast lead times (as little as 3-6 days for small batches)
  • Whether you need functional prototypes or end-use parts, FlagShip’s vacuum casting solutions scale with your needs, reducing costs without compromising quality.

    • Ready to get started on your Vacuum Casting Service?



    Types of Vacuum Casting

    Vacuum casting encompasses several specialized techniques tailored to different materials and applications:

  • Polyurethane Vacuum Casting: The most common type, using two-part polyurethane resins to create rigid or flexible parts. Ideal for mimicking the properties of engineering plastics (ABS, PP, PC).
  • Silicone Vacuum Casting: Uses liquid silicone rubber (LSR) to produce heat-resistant, flexible components. Suitable for gaskets, seals, and medical devices.
  • Rubber Vacuum Casting: Focuses on elastomeric materials, delivering parts with high durability and elasticity, often used in automotive and industrial seals.
  • Overmolding Vacuum Casting: Combines multiple materials (e.g., rigid plastic with soft rubber) in a single process, enabling complex, multi-material parts.

    • Ready to get started on your Vacuum Casting Service?



    Materials for Vacuum Casting

    Vacuum casting supports a diverse range of materials to match specific functional requirements:

    • Polyurethanes: Available in rigid (Shore D 60-85), flexible (Shore A 30-90), and foam variants. Resistant to impact, chemicals, and UV exposure.
    • Silicone Rubbers: Heat-resistant (up to 200°C), biocompatible, and excellent for electrical insulation. Ideal for medical tools and high-temperature applications.
    • Thermoplastic Elastomers (TPE): Offer rubber-like elasticity with plastic processability, suitable for grips, gaskets, and wearables.
    • Epoxies: Provide high strength and dimensional stability, often used for structural components and electronics housings.

    Each material can be customized with additives for flame resistance, conductivity, or color matching.

    Ready to get started on your Vacuum Casting Service?

    Finishes for Vacuum Cast Parts

    Vacuum cast parts can be enhanced with a variety of finishes to meet aesthetic and functional needs:

    • Painting: Custom colors, gloss/matte finishes, and texture coating (e.g., soft-touch, metallic).
    • Plating: Chrome, nickel, or gold plating for a decorative, corrosion-resistant surface.
    • Texturing: Mold-in patterns (brushed, embossed, or custom designs) for improved grip or branding.
    • Polishing: High-gloss finishes for cosmetic parts, achieving a mirror-like surface.
    • Vapor Deposition: PVD coatings for enhanced hardness and wear resistance, ideal for industrial components.


    Applications of Vacuum Casting

    Vacuum casting is widely used across industries for its versatility and precision:

  • Automotive: Prototyping interior trim, dashboard components, and rubber seals.
  • Medical Devices: Producing custom enclosures, surgical tools, and biocompatible parts.
  • Consumer Electronics: Creating phone cases, wearables, and cable management components.
  • Aerospace: Low-volume production of lightweight, high-strength parts for drones and aircraft.
  • Toys & Recreation: Manufacturing detailed figurines, game pieces, and durable outdoor equipment.

    • Ready to get started on your Vacuum Casting Service?



    Advantages & Disadvantages of Vacuum Casting

    Advantages:

    • Cost-effective for small batches (10-500 units) compared to injection molding.
    • Fast turnaround (molds ready in 1-2 days, parts in 3-6 days).
    • High detail replication, including fine textures and complex geometries.
    • Wide material selection to match end-use properties.
    • No tooling costs for low-volume runs (silicone molds are reusable 20-50 times).

    Disadvantages:

    • Cost-effective for small batches (10-500 units) compared to injection molding.
    • Fast turnaround (molds ready in 1-2 days, parts in 3-6 days).
    • High detail replication, including fine textures and complex geometries.
    • Wide material selection to match end-use properties.
    • No tooling costs for low-volume runs (silicone molds are reusable 20-50 times).

    Ready to get started on your Vacuum Casting Service?

    Ready to get started on your Injection Molding project?

    Free shipping available for domestic CNC orders