Vacuum Casting Services
High-quality vacuum casting parts for prototyping, bridge production, and short runs – delivered in as fast as 7 days.
- Tight tolerances down to ±0.05 mm
- No tooling investment required
- Suitable for complex geometries & fine details
- Supports multiple materials & finishes
What is Vacuum Casting?
Vacuum casting is a low-cost manufacturing process used to produce high-quality plastic parts in small volumes. It works by creating a silicone mold from a master model and using a vacuum to cast polyurethane or similar materials with high accuracy and surface detail.
This process is ideal for functional prototypes, visual models, bridge production, and low-run end-use parts—especially when fast turnaround and tooling flexibility are critical.
- Functional prototypes for testing
- Short-run production without hard tooling
- Appearance models and presentation samples
- Bridge production before injection molding
- Color, transparency, or texture simulation
Kemal’s Vacuum Casting Capabilities
At Kemal, we offer advanced vacuum casting services tailored for low-volume, high-precision plastic parts. Our in-house team and equipment ensure tight tolerances, smooth surface finishes, and rapid turnaround for various prototype and short-run production needs.
| Capability | Specification |
|---|---|
|
Maximum Part Size |
800 × 600 × 400 mm
|
|
Minimum Wall Thickness |
0.75 mm |
|
Dimensional Tolerance |
±0.05 mm (standard), ±0.02 mm (with validation) |
|
Typical Mold Life |
15–25 shots per silicone mold |
|
Surface Quality |
High detail replication, fine texture supported |
|
Color Options |
Custom RAL/Pantone colors, transparent & tinted
|
|
Material Types |
ABS-like, PP-like, PC-like, rubber-like, clear PU |
|
Lead Time |
As fast as 7 days for most projects |
|
Certifications |
ISO 9001, ISO 13485, IATF 16949 |
Need something specific? Contact us for tailored casting support.
Vacuum Casting Materials
Kemal offers a wide selection of casting resins that simulate the mechanical, thermal, and aesthetic properties of common engineering plastics and elastomers. From rigid ABS-like parts to flexible rubber-like components, our vacuum casting materials are suitable for prototypes, functional tests, and small-batch end-use parts.
| Material Type | Simulated Properties | Common Uses |
|---|---|---|
|
ABS-like Resin |
Rigid, impact-resistant, dimensionally stable |
Enclosures, housings, mechanical parts |
|
PP-like Resin |
Semi-flexible, fatigue-resistant, chemical-tolerant |
Snap fits, clips, covers |
|
PC-like Resin |
Transparent, tough, good heat resistance |
Lenses, windows, clear casings |
|
Rubber-like Resin |
Flexible, soft, Shore A 30–90 available |
Seals, gaskets, soft-touch components |
|
High-transparency PU |
Optical-grade clarity, UV-stable optional |
Light guides, cosmetic transparent parts |
Not sure which material fits your application? Request a free consultation
Vacuum Casting Color Options
Practical and flexible color solutions for prototypes, visual models, and short-run production.
Kemal supports a wide range of color options—whether you need transparent, tinted, or brand-matched components. Colors are integrated into the resin during casting, not simply painted on the surface, ensuring long-term consistency and durability.
Standard Colors
Black, white, and gray are available by default. Ideal for functional parts, engineering tests, and quick validation.
Transparent & Tinted
Crystal-clear or lightly colored parts for light guides, displays, and internal structure visibility.
Pantone / RAL
Accurately match your brand colors by specifying Pantone or RAL codes. Pigments are blended into the casting resin for uniform color.
Rubber-like Material Colors
Rubber-tone black, gray, and custom soft shades available for flexible or silicone-like parts.
Optional Painted Finishes
For high-appearance models, post-processing options like painting, coating, or texture application are available on request.
Vacuum Casting Solutions
Your trusted solution provider for every stage of product development—from engineering prototypes to production-ready samples.
Prototyping
Quickly produce functional prototypes that simulate injection-molded parts. Vacuum casting allows fast iterations and high accuracy, perfect for fit testing, design validation, and engineering trials—without committing to steel molds.
- Ideal for: engineering validation, functional testing, pre-launch R&D
Low-Volume Production
Need 20 to 200 parts, fast? Vacuum casting bridges the gap between prototyping and injection molding. We support a wide range of rigid and flexible polyurethane resins that mimic ABS, PP, PC, and rubber-like properties—delivered in as fast as 7 days.
- Perfect for: pilot production, market testing, early customer orders
Presentation-Ready Samples
Looking for visually refined models for sales demos or investor pitches? Our casting service supports color-matched parts, transparent finishes, and soft-touch textures—ideal for marketing models, visual approvals, or brand showcase kits.
- Best for: trade shows, product launches, visual presentations
Advantages of Vacuum Casting
Vacuum casting offers a fast, flexible, and cost-effective solution for producing high-quality plastic parts in small quantities. It’s widely used for rapid prototyping, bridge production, and functional testing.
Low Cost Without Tooling Investment
No need for expensive steel molds—ideal for early-stage projects or limited production runs.
High-Fidelity Surface Finish
Accurately replicates fine details and textures from the master model.
Wide Material & Color Options
Casts can simulate ABS, PP, PC, rubber, and more—available in transparent, tinted, or custom colors.
Fast Turnaround Time
Parts can be delivered in as little as 7–10 business days.
Excellent for Complex Geometries
Silicone molds allow undercuts, thin walls, and intricate designs with ease.
Great for Testing Before Injection Molding
Perfect for verifying form, fit, and function before committing to hard tooling.
Why Choose Kemal for Vacuum Casting
In-House Mold Making
We fabricate silicone molds in-house to ensure precision and repeatability for every part.
Fast Turnaround Times
Most vacuum casting projects are completed within 7–10 business days, even for complex geometries.
Wide Material Compatibility
We offer a variety of rigid, flexible, transparent, and color-matched materials to simulate injection-molded parts.
Low-Volume Friendly
No MOQ. Whether it’s 1 part or 100, we scale with your needs without compromising quality.
Quality Assurance
Dimensional checks, surface finish control, and certifications like ISO 9001 and ISO 13485 ensure reliability.
Engineering Support
We provide free DFM reviews and offer guidance from design to delivery to minimize risk and speed up development.
Industries We Served
Reliable vacuum casting solutions trusted across multiple industries—from precision engineering to consumer-grade products.
Industrial Equipment
Connectors, control knobs, panel covers, functional mock-ups
Robotics
Sensor mounts, protective shrouds, flexible grips, housing frames
Home Appliances
Switch buttons, outer shells, handles, aesthetic mock-ups
FAQs
Yes. We offer Pantone and RAL color matching by mixing pigments directly into the casting resin. This ensures consistent, embedded color throughout each part—not just surface coating. Transparent and tinted finishes are also available for visual models or light-transmitting parts.
Need a specific brand color? Just send us the color code or a sample reference—we’ll match it.
The typical dimensional tolerance for vacuum-cast parts is ±0.05 mm. For more precise features or critical applications, we can achieve tighter tolerances with a Design for Manufacturability (DFM) review before production.
Have specific tolerance requirements? Contact us for a customized evaluation.
The typical lead time for vacuum casting is 7–10 business days for most parts, depending on complexity and order volume. For urgent projects, we offer expedited production with a quicker turnaround upon request.
Need a faster delivery? Contact us to discuss your timeline.
No, there is no minimum order quantity (MOQ) for our vacuum casting services. We support quantities as low as 1 part, making it ideal for prototypes, small batches, or initial market tests.
Yes, we offer free Design for Manufacturability (DFM) reviews before starting production. Our engineering team will evaluate your design to ensure manufacturability, optimize part features, and provide recommendations for improving cost efficiency and part performance.
Upload your CAD file, and we’ll provide a detailed DFM review before proceeding with tooling.
We accept a variety of 3D CAD and 2D file formats for vacuum casting projects, including:
- STEP (.step, .stp)
- IGES (.igs, .iges)
- STL (.stl)
- Parasolid (.x_t, .x_b)
- SolidWorks (.sldprt)
- AutoCAD (.dwg, .dxf)
For the most accurate quote and efficient process, we recommend submitting 3D models in STEP or IGES format.
What if I don’t have these file formats?
No problem! If you don’t have a 3D CAD file in the required formats, don’t worry. You can still work with us:
- 2D drawings (PDF, JPEG, PNG, etc.)
- Scan data (e.g., 3D scan files or photos of physical parts)
- Concept sketches or hand-drawn designs
Our team can assist you in converting these into the correct format for production. If you are unsure how to proceed or face any difficulties uploading files, just reach out to us! We’re here to help guide you through the process.
Send us what you have, and we’ll work with you to get your project on track.
Vacuum casting is a process that uses a silicone mold to replicate parts with high accuracy and fine details. The steps are as follows:
- Master Model Creation: A 3D model or prototype is created using CNC machining or 3D printing. This model will serve as the base for creating the mold.
- Silicone Mold Making: The master model is placed in a box and silicone rubber is poured around it to form the mold. The mold is then cured to ensure it’s solid and durable.
- Vacuum Casting: The silicone mold is placed in a vacuum chamber. Polyurethane or other resins are poured into the mold, and the vacuum removes air bubbles, ensuring a perfect fill.
- Part Curing & Removal: The cast part is allowed to cure in the mold. Once cured, the part is removed, and any finishing (like painting or sanding) is done to match the desired specifications.
- Final Product: The result is a high-quality, functional part or prototype that accurately represents the original design.
Have a part ready to be cast? Upload your file and get started with our service!
Vacuum casting is cost-effective compared to traditional injection molding, especially for low-volume production and prototypes. Since it doesn’t require expensive steel molds, the upfront costs are significantly lower. This makes it ideal for projects where you need high-quality parts in small quantities (typically 10–200 units), or for testing before committing to larger-scale production.
However, costs can vary depending on factors like part complexity, material choices, and lead time. Our team will work with you to provide an accurate quote based on your specific project requirements.
Want to know the exact cost for your project? Upload your CAD file and get a detailed quote.
The minimum thickness for vacuum casting parts is typically 0.75 mm. This thickness is suitable for most standard materials, ensuring that the parts have good structural integrity and can withstand handling during post-processing. However, this can vary depending on the material used, as some resins are more flexible and can support thinner walls, while others may require slightly thicker parts for durability.
For example:
- Flexible materials (rubber-like resins): Can often be molded to thinner walls, down to around 0.5 mm.
- Rigid materials (ABS-like, PC-like): Typically require a minimum thickness of 0.75 mm to 1.0 mm to ensure proper strength and finish.
It’s also important to consider the part design—features such as sharp angles, undercuts, or intricate geometries may require thicker walls for stability. Thinner parts may be possible for certain applications, but we recommend consulting with our team to ensure the best manufacturability and performance of your parts.
