Vacuum Casting Service: From Prototype to Low-Volume Production
Professional vacuum casting service from FIRMFG. Silicone molds, 20+ PU resin options, ±0.1mm tolerance, and 5-day turnaround. ISO 9001 certified quality for low-volume production up to 500 parts.
Vacuum Casting Service: From Prototype to Low-Volume Production
FIRMFG's vacuum casting service bridges the gap between prototyping and full-scale production. Using silicone molds and liquid polyurethane resins, we produce parts that look, feel, and perform like injection-molded components — at a fraction of the tooling cost and lead time. Whether you need a single functional prototype or 500 production-ready parts, our service delivers consistent quality with every shot.
Our capabilities span the entire vacuum casting workflow: master pattern creation, silicone mold making, PU resin casting, silicone parts casting, multi-material overmolding, color matching, and full post-processing. With 20+ material options simulating ABS, PC, PP, TPU, silicone, and specialty grades, we match your production material properties with up to 90% fidelity.
Every project is backed by our ISO 9001:2015 certified quality management system, with dimensional inspection reports and First Article Inspection included as standard. Standard turnaround is 5–7 days, with Rush, Express, and Super Rush options available for time-critical projects. Ready to start? Request a quote and receive a detailed price and lead time within 24 hours.
Vacuum Casting Service Specifications
Key capabilities, delivery standards, and quality metrics of our vacuum casting service at FIRMFG.
| Specification | Value |
|---|---|
| Standard Lead Time | 5 – 7 days |
| Maximum Part Size | 600 × 400 × 400 mm |
| Dimensional Tolerance | ±0.1 mm (±0.004") |
| Material Options | 20+ PU resin grades |
| Mold Life | 20 – 30 copies per mold |
| Maximum Production Volume | 500 parts per project |
| Quality Standard | ISO 9001:2015 Certified |
Our Vacuum Casting Service Capabilities
From silicone mold making to multi-material overmolding and full assembly, our vacuum casting service covers every stage of the production workflow.
Silicone Mold Making
We create high-fidelity silicone molds from your master pattern using addition-cure (platinum) silicone rubber under vacuum degassing. Each mold captures fine details down to 0.3 mm and is rated for 20–30 casting cycles. Mold design includes optimized parting lines, gating, and venting to minimize defects and maximize mold lifespan.
Addition-cure silicone, 25–30 copies/mold, 0.3 mm detail capture
PU Resin Casting
Two-component polyurethane resin is mixed, degassed, and poured into the silicone mold under vacuum. This eliminates trapped air bubbles and ensures complete filling of intricate geometries. We offer 20+ PU resin grades simulating ABS, PC, PP, TPU, and engineering plastics with tunable hardness from Shore 20A to Shore 85D.
20+ PU resin grades, Shore 20A – 85D, vacuum-assisted filling
Silicone Parts Casting
For applications requiring heat resistance, biocompatibility, or extreme flexibility, we cast liquid silicone rubber (LSR) parts directly. Available in Shore 20A–60A hardness, these parts withstand continuous temperatures up to 200°C and are suitable for gaskets, seals, medical components, and overmolded grips.
Shore 20A – 60A, 200°C heat resistance, biocompatible options
Multi-Material Casting
Produce overmolded and multi-material parts in a single casting cycle. We cast rigid substrates first, then overmold flexible TPU-like or silicone layers for soft-touch grips, seals, and dual-hardness assemblies. This eliminates assembly steps and achieves production-grade multi-material prototypes.
Rigid + flexible overmolding, dual-durometer parts, single-cycle casting
Color Matching & Painting
Achieve exact Pantone, RAL, or custom color matches with our in-house painting and color-matching service. We offer matte, glossy, satin, and textured finishes, as well as metallic and soft-touch coatings. UV-stable paints ensure colorfastness for prototypes that undergo outdoor or consumer testing.
Pantone/RAL matching, matte/gloss/textured finishes, UV-stable paints
Post-Processing & Assembly
Beyond casting, we provide comprehensive post-processing including gate trimming, sanding, polishing, pad printing, silk screening, and thread insert installation. Full sub-assembly and packaging services are available, delivering ready-to-ship or ready-to-install components directly to your production line.
Trimming, polishing, pad printing, insert installation, sub-assembly
How to Order Vacuum Casting Service
From CAD upload to shipping, our streamlined 5-step process delivers production-quality parts in 5–7 days. Here is exactly what happens at each stage.
Step 1: Upload CAD Files
Submit your 3D CAD files (STEP, IGES, STL, or X_T) through our online quote portal or by email. Include material specifications, desired surface finish, color requirements, and target quantity. Our engineers review every file for manufacturability and provide DFM feedback at no charge.
Step 2: Receive Quote (24h)
Within 24 hours, you receive a detailed quote including mold fee, per-part cost, finishing options, material recommendation, and lead time. Our engineers suggest the optimal resin grade, Shore hardness, and mold strategy to meet your functional and cosmetic requirements.
Step 3: Master Pattern Creation
Upon quote approval, we create a master pattern using SLA 3D printing for complex geometries or CNC machining for high-precision metal-like finishes. The master is sanded, primed, and polished to your specified surface finish, as every detail transfers to the final cast parts at 99% fidelity.
Step 4: Silicone Mold & Casting
A silicone mold is created from the master pattern under vacuum. Polyurethane resin is then mixed, degassed, and cast into the mold inside a vacuum chamber. Each shot cures in an oven at 60–70°C for 2–4 hours. Multiple parts are cast in parallel to meet your quantity requirements.
Step 5: Quality Inspection & Shipping
Finished parts undergo dimensional inspection using CMM and calipers, with a full dimensional inspection report provided. Parts are trimmed, finished, and packaged to your specifications. We ship globally via DHL, FedEx, or UPS with tracking, typically arriving within 2–4 business days.
Turnaround Times & Rush Options
Choose the turnaround tier that fits your project timeline. All tiers include full quality inspection and global shipping.
| Service Tier | Lead Time | Price Premium | What's Included |
|---|---|---|---|
| Standard | 7 days | Base price | Master pattern, silicone mold, casting, basic finishing, dimensional inspection report, standard global shipping |
| Rush | 5 days | +30% | Expedited master pattern, priority mold making, accelerated curing, full finishing, inspection report, expedited shipping |
| Express | 3 days | +60% | Same-day pattern start, dual-shift mold making, fast-cure resin, full finishing, inspection report, express shipping |
| Super Rush | 48 hours | +100% | Immediate project kickoff, dedicated engineering team, fast-cure resin system, essential finishing, inspection report, next-flight-out shipping |
Lead times are calculated from quote approval to shipping. Standard shipping (2–4 business days) is included in all tiers. Express and Super Rush include expedited shipping.
Quality Assurance & Certifications
Every vacuum casting project is backed by our ISO 9001:2015 quality management system and documented inspection processes.
ISO 9001:2015 Certified
Our facility operates under an ISO 9001:2015 certified quality management system. Every vacuum casting project follows documented procedures for material handling, process control, and inspection, ensuring consistent quality from first article to final part.
Dimensional Inspection Report
Every order ships with a dimensional inspection report. Critical dimensions are measured using CMM (Coordinate Measuring Machine) and calibrated digital calipers, with results documented against your CAD nominal values and specified tolerances.
Material Certification
We provide material certificates for all PU resins and silicones used in your project, including manufacturer datasheets, Shore hardness verification, and compliance documentation for FDA, RoHS, or REACH requirements where applicable.
First Article Inspection
Before full production begins, the first cast part undergoes First Article Inspection (FAI). You receive photos, dimensional data, and material confirmation for approval before we proceed with the remaining quantity, eliminating surprises on delivery.
Materials Available for Vacuum Casting
Our material library includes 20+ polyurethane resin grades and liquid silicones that simulate production plastics across the full hardness spectrum.
| Material | Hardness | Tensile Strength | Applications |
|---|---|---|---|
| ABS-like PU | Shore 80D | 40 – 55 MPa | Rigid prototypes, housings, enclosures, consumer electronics |
| PC-like PU | Shore 85D | 50 – 65 MPa | Tough transparent parts, lenses, display covers, light guides |
| PP-like PU | Shore 70D | 25 – 35 MPa | Living hinges, snap-fits, containers, tough semi-flexible parts |
| TPU-like PU | Shore 60A – 90A | 10 – 30 MPa | Flexible parts, seals, gaskets, overmolded grips, wearables |
| Silicone (LSR) | Shore 20A – 60A | 5 – 12 MPa | Heat-resistant parts, medical components, seals, gaskets, valves |
| Transparent PU | Shore 70D – 85D | 45 – 60 MPa | Clear parts, light pipes, display lenses, glass-like prototypes |
| High-Temp PU | Shore 80D – 85D | 45 – 55 MPa | 120°C continuous use, automotive under-hood, thermal housings |
| Food-Grade PU | Shore 70D – 85D | 35 – 50 MPa | FDA compliant, food contact, kitchenware, beverage prototypes |
All materials are available in custom colors. Specialty grades including flame-retardant, UV-stable, and ESD-safe PU resins are available upon request. Material certifications and datasheets are provided with every order.
Pricing Structure & Volume Discounts
Vacuum casting pricing consists of a one-time mold fee plus per-part casting and finishing costs. Volume discounts apply as mold cost is amortized across more parts.
Mold Fee
$150 – $500
One-time silicone mold creation, reusable for 20–30 casting cycles. Cost depends on part size and complexity.
Per-Part Casting
$15 – $80
PU resin + labor + curing per shot. Varies with part volume, material grade, and Shore hardness.
Finishing
$5 – $30
Painting, texturing, pad printing, assembly, and insert installation per part. Optional, based on requirements.
Volume Discount: Unit Cost at Different Quantities
| Order Quantity | Unit Cost | Notes |
|---|---|---|
| 1 unit | $550 | Includes master pattern + mold + 1 cast part |
| 5 units | $110 | Mold cost amortized across 5 parts |
| 10 units | $70 | Per-part cost becomes dominant |
| 20 units | $55 | Full single-mold life, maximum efficiency |
| 50 units | $48 | Multi-mold production, volume pricing |
| 100 units | $45 | Maximum volume discount tier |
Example based on a 100 × 60 × 40 mm ABS-like part with matte finish. Actual quotes vary with geometry, material, finishing, and shipping destination. Contact us for a custom quote tailored to your project.
Vacuum Casting Service FAQ
Answers to the most common questions about our vacuum casting service at FIRMFG.
QWhat is the minimum order quantity for vacuum casting service?
There is no strict minimum order quantity — you can order as few as a single prototype part. However, since each project requires a one-time mold fee ($150–500) and master pattern creation, ordering 5 or more parts significantly reduces the per-part cost as the mold cost is amortized across the batch. For quantities above 100, contact us for custom volume pricing.
QWhat is the lead time for vacuum casting service?
Standard turnaround is 5–7 days from quote approval to shipping. This includes master pattern creation (1–2 days), silicone mold making (1–2 days), and casting with curing (2–3 days). Rush service delivers in 5 days (+30%), Express in 3 days (+60%), and Super Rush in 48 hours (+100%). Each additional batch from an existing mold takes 2–3 days.
QWhat material options are available for vacuum casting?
We offer 20+ polyurethane resin grades that simulate production plastics: ABS-like (rigid, Shore 80D), PC-like (tough, transparent, Shore 85D), PP-like (tough, semi-flexible, Shore 70D), TPU-like (flexible, Shore 60A–90A), and liquid silicone (Shore 20A–60A). Specialty grades include transparent PU, high-temperature PU (120°C), and FDA-compliant food-grade PU. Our engineers recommend the best material for your application.
QWhat accuracy and precision can vacuum casting achieve?
Vacuum casting achieves dimensional tolerances of ±0.1 mm (±0.004") for features under 100 mm and ±0.15% for larger dimensions. Surface finish replicates the master pattern at 99% fidelity — a polished master produces polished parts. Fine details down to 0.3 mm can be reproduced. Every order includes a dimensional inspection report verifying critical dimensions against your CAD nominal values.
QHow much does a vacuum casting mold cost?
A silicone mold costs $150–500 depending on part size, complexity, and material. This is a one-time fee — the mold is reusable for 20–30 casting cycles. Compared to injection molding tooling ($5,000–50,000), vacuum casting molds are 95% cheaper and take 1–2 days to produce versus 4–8 weeks. The mold fee is included in your per-project quote and amortized as order quantity increases.
QDo you offer shipping and delivery for vacuum cast parts?
Yes, we ship globally via DHL, FedEx, and UPS with full tracking. Standard shipping is included in all turnaround tiers and typically arrives within 2–4 business days. Express and Super Rush tiers include expedited and next-flight-out shipping respectively. Parts are individually bagged and packed in protective foam to prevent damage during transit, with packaging customized to your requirements.
Why Choose FIRMFG for Vacuum Casting
With 15+ years of experience, 100+ machines, and ISO 9001 certified quality, FIRMFG delivers production-grade vacuum cast parts faster and more cost-effectively than the competition.
Advanced Equipment
Our facility houses 100+ machines including industrial vacuum chambers (600×400×400mm), programmable mixing systems, curing ovens (40–150°C), and pressure pots for bubble-free transparent parts. This equipment capacity enables parallel production of multiple molds and cast parts simultaneously.
15+ Years Experience
Since 2010, FIRMFG has delivered vacuum cast parts for over 5,000 projects across medical, automotive, electronics, and consumer products. Our engineering team brings deep expertise in mold design, material selection, and process optimization to every project, ensuring first-time-right results.
20+ Material Options
With 20+ polyurethane resin grades and liquid silicones in stock, we match production material properties for virtually any application. From rigid ABS-like to flexible TPU-like to food-grade and high-temperature resins, our material library covers the full spectrum of engineering plastics.
5-Day Turnaround
Standard turnaround is 5–7 days, with Rush (5 days), Express (3 days), and Super Rush (48 hours) options available. Our streamlined workflow from CAD upload to shipping ensures you receive production-quality parts faster than any competing process at this volume.
ISO 9001 Quality
Our ISO 9001:2015 certified quality management system governs every step from material handling to final inspection. Every order ships with a dimensional inspection report, and First Article Inspection ensures your parts meet specifications before full production proceeds.
Competitive Pricing
Mold fees start at $150 and per-part costs range from $15–80, making vacuum casting 95% cheaper than injection molding tooling for quantities under 500. Volume discounts apply at 5, 10, 20, 50, and 100 units, with unit costs dropping to $45 at the 100-unit tier.
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Learn MoreStart Your Vacuum Casting Project Today
Upload your CAD files and get a free vacuum casting quote within 24 hours. Our engineers provide DFM feedback and material recommendations at no cost. ISO 9001 certified quality, tolerances to ±0.1mm, 20+ material options, and 5-day turnaround.