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Vacuum Casting & Reaction Injection Moulding

Small batches with tunable colour and a choice of soft or hard resins, finished to production-grade surface quality.

Vacuum casting produces small batches of cosmetic and functional covers without committing to steel tooling. Reaction injection moulding (RIM) covers larger enclosures and structural parts that are too big or too low-volume for conventional tooling. Both run at the same base as the machining and printing workshops, so a master pattern machined on Monday can be a cast shell on the inspection bench that week.

Colour and hardness, tunable

Soft or hard resins, colour matched to the sample you send. Soft-touch overmoulded details are cast in the same programme as rigid shells.

10 to a few thousand parts

Small-batch economics: casting and rapid tooling carry the volume between prototype and production moulding.

Master pattern machined here

The pattern is CNC-machined and precision polished at the base, then measured. Mould quality follows pattern quality.

Vacuum casting procedure
01CNC machining of the master patternPattern machined from production-equivalent stock and precision polished.
02Mould frame fabricationFrame built and the pattern located inside it.
03Mould separationParting line, gates and vents decided against the draw direction.
04Vacuum castingResin pour under vacuum, so cosmetic faces hold detail without bubbles.
05Mould opening and extractionCure, demould and trim. White shells move to finishing.
06Mould sealing for batchSealed for repeat pours across the cover batch.
Moulds and cast batches
Machined master pattern with its mould halves Machined master pattern with its mould halves
Silicone mould cured in the casting frame Silicone mould cured in the casting frame
Mould prepared for vacuum pour Mould prepared for vacuum pour
Resin poured into a mould box before cure Resin poured into a mould box before cure
Pink master pattern inside an opened silicone mould Pink master pattern inside an opened silicone mould
White cast shells removed from the mould White cast shells removed from the mould
CMM-side machining of a casting mould CMM-side machining of a casting mould
Batch of green cast plastic brackets Batch of green cast plastic brackets
Vacuum casting workshop Vacuum casting workshop
Cast parts after finishing
Vacuum-cast soft-resin part Vacuum-cast soft-resin part
Overmoulded soft-touch component Overmoulded soft-touch component
Batch of black cast housings Batch of black cast housings
Finished cast covers after surface treatment Finished cast covers after surface treatment
Small-batch cast body covers Small-batch cast body covers
Questions buyers ask
How many parts can vacuum casting produce before tooling is needed?

Vacuum casting and rapid tooling bridge prototype to moulded volume, from 10 parts to a few thousand. A silicone mould has a limited copy count and is re-made from the master pattern when it is exhausted, which suits cosmetic cover batches.

Can cast covers match the production surface?

Yes. Cast parts are finished to production-grade surface quality with the treatment list on the materials page, including painting, sandblasting, polishing and silk-screen.

What is the difference between vacuum casting and RIM?

Vacuum casting pours resin into a silicone mould under vacuum and suits cosmetic parts in soft or hard resins. Reaction injection moulding covers larger enclosures and structural parts that are too big or too low-volume for conventional tooling.

Also read: vacuum casting versus injection moulding, and where the break-even sits.

Start a programme

Send the drawings, get a DFM view back

Rocky Chen replies with a process route, the tolerance risks we see in your data and a quotation — usually within one working day.

Enquiry form and details

ContactRocky Chen
Whatsapp+86 138 2330 4476
Emailsales@everoyalprecision.com
BaseSuzhou, Jiangsu, China. Visits by appointment.