Small Batch Vacuum Casting: From 1 to 100 Parts Without Mold Costs
Order 1 to 100 production-quality parts with no minimum order quantity. Silicone mold vacuum casting delivers ABS, PC, TPU, and silicone parts in 5–7 days at a fraction of injection molding tooling cost. ISO 9001 certified quality at FIRMFG.
Small Batch Vacuum Casting: From 1 to 100 Parts Without Mold Costs
Small batch vacuum casting is the ideal manufacturing solution when you need between 1 and 100 parts without the prohibitive tooling costs of injection molding. Using a single silicone mold, we produce production-quality polyurethane parts that match the look, feel, and performance of your final product — with no minimum order threshold.
At FIRMFG, our small batch vacuum casting service delivers parts with tolerances of ±0.1 mm, 99% master pattern fidelity, and over 20 material options that simulate ABS, PC, PP, TPU, silicone, and transparent plastics. Each silicone mold produces 20–30 copies, and molds can be stored for repeat orders — making this the most cost-effective process for samples, niche products, and low-volume production runs.
Whether you need a single prototype for investor demos, 50 replacement parts for discontinued equipment, or 100 market test units before committing to injection molding, small batch vacuum casting bridges the gap between prototyping and full-scale production. Request a quote to get an instant price and lead time for your parts.
Small Batch Vacuum Casting Specifications
Key capabilities and parameters for small batch vacuum casting at FIRMFG.
| Specification | Value |
|---|---|
| Minimum Order Quantity | 1 piece (no MOQ) |
| Per-Mold Yield | 20 – 30 copies per mold |
| Lead Time | 5 – 7 days (first batch) |
| Dimensional Tolerance | ±0.1 mm (±0.004") |
| Maximum Part Size | 600 × 400 × 400 mm |
| Material Options | 20+ PU resin grades |
| Mold Cost | $150 – $500 per mold |
Why Choose Small Batch Vacuum Casting?
Small batch vacuum casting offers unique advantages for low-volume production that no other manufacturing process can match.
No Minimum Order
Order from 1 to 100 parts with no MOQ threshold. Whether you need a single sample or a small production run, vacuum casting accommodates your exact quantity.
No Expensive Tooling
Silicone molds cost $150–$500 compared to $5,000–$50,000 for injection molding steel tools. No upfront tooling investment required.
Fast 5–7 Day Turnaround
From CAD file to finished parts in just 5–7 days. No weeks of waiting for mold tooling — get production-quality parts in days.
Design Flexibility
Change designs between batches without mold modification costs. Each new design simply requires a new master pattern and mold.
Material Variety (20+)
Over 20 PU resin grades simulate ABS, PC, PP, TPU, silicone, and transparent plastics. Match production material properties.
Cost-Effective for Small Runs
Per-unit cost drops from $550 for 1 part to $25 for 100 parts. Mold cost amortizes across the batch for significant savings.
Batch Size Optimization: Cost Per Unit
The per-unit cost of vacuum casting drops dramatically as batch size increases, because the one-time mold cost is amortized across more parts.
| Batch Quantity | Total Cost | Per-Unit Cost | Savings vs 1 Part |
|---|---|---|---|
| 1 part | $550 | $550 | — |
| 5 parts | $550 | $110 | 80% |
| 10 parts | $650 | $65 | 88% |
| 20 parts | $900 | $45 | 92% |
| 50 parts | $1,500 | $30 | 95% |
| 100 parts | $2,500 | $25 | 95.5% |
Mold Cost Amortization Curve
The curve illustrates how mold cost amortization drives down per-unit cost. Ordering 20 parts instead of 1 reduces cost per part by 92%. Beyond 50 parts, diminishing returns set in as additional molds are needed.
Detailed Per-Unit Cost Breakdown
Understand exactly where your money goes. This breakdown shows how mold cost, material cost, and finishing cost combine at each quantity level.
| Quantity | Mold Cost | Part Cost | Finishing Cost | Total Cost | Per-Unit Cost |
|---|---|---|---|---|---|
| 1 unit | $300 | $200 | $50 | $550 | $550 |
| 5 units | $300 | $200 | $50 | $550 | $110 |
| 10 units | $300 | $250 | $100 | $650 | $65 |
| 20 units | $300 | $400 | $200 | $900 | $45 |
| 50 units | $600 | $600 | $300 | $1,500 | $30 |
| 100 units | $900 | $1,000 | $600 | $2,500 | $25 |
How Small Batch Cost Structure Works
- Mold cost is a one-time fixed cost ($150–$500) that does not change with quantity. This is why per-unit cost drops sharply at low volumes.
- Part cost scales linearly with quantity — more parts means more resin and labor. Volume discounts on resin reduce per-part material cost at higher quantities.
- Finishing cost includes trimming, sanding, painting, and assembly. At 50+ parts, batch finishing processes reduce per-unit finishing cost.
- Additional molds are needed for batches exceeding 30 parts. At 50 parts, 2 molds are required; at 100 parts, 3–4 molds are needed.
Silicone Mold Reusability & Economics
One silicone mold produces 20–30 parts. Understanding mold lifespan and reuse options helps you optimize your small batch strategy.
One Mold = 20–30 Parts
A single silicone mold reliably produces 20–30 copies before degradation. This covers most small batch requirements without additional mold costs.
Second Mold for Larger Batches
If your batch exceeds 30 parts, a second mold is required at $150–$300. This is factored into the per-unit cost for 50+ part orders.
Mold Storage for Repeat Orders
We store molds for up to 6 months. Place repeat orders without paying mold setup costs again — just pay per-part casting and finishing.
Mold Life Factors
Mold lifespan depends on part geometry, resin type, draft angles, and demolding technique. Simple parts can exceed 30 copies; complex parts may yield 15–20.
Recommended Materials for Small Batch
These four material categories cover the majority of small batch vacuum casting applications. Each is optimized for specific use cases and batch sizes.
| Material | Recommended Batch Size | Cost | Cure Time | Description |
|---|---|---|---|---|
| ABS-like PU Resin | 1 – 100 parts | $15 – $30/part | 2 – 4 hours | General purpose, rigid and impact-resistant |
| PC-like Transparent PU | 5 – 50 parts | $25 – $45/part | 3 – 5 hours | Transparent, tough, glass-like finish |
| TPU-like Flexible PU | 1 – 50 parts | $20 – $40/part | 3 – 4 hours | Flexible, elastomeric, rubber-like |
| Silicone Casting Resin | 1 – 30 parts | $30 – $50/part | 4 – 6 hours | Heat resistant, biocompatible, gaskets |
Example based on a 100 × 60 × 40 mm part with matte finish. Actual costs vary with part geometry, wall thickness, and finishing requirements. Contact us for material samples.
Quality Control: 100% Inspection for Small Batches
Small batch orders allow 100% inspection — every single part is verified, not just statistical samples. ISO 9001:2015 certified quality system.
Full Dimensional Inspection
Every part measured with CMM and calipers to verify ±0.1mm tolerance compliance on critical dimensions.
Visual Surface Check
100% visual inspection for surface defects, bubbles, flow lines, and finish quality against master pattern.
Material Verification
Shore hardness testing and material property verification to ensure PU resin matches specified grade.
First Article Approval
First article inspection report provided with every order, including dimensional data and material certification.
ISO 9001:2015 Certified Quality
FIRMFG operates under an ISO 9001:2015 certified quality management system. Every small batch order includes a first article inspection report and material certification at no additional cost.
Small Batch Vacuum Casting FAQ
Answers to the most common questions about small batch vacuum casting at FIRMFG.
QWhat is the minimum order quantity for small batch vacuum casting?
The minimum order quantity for small batch vacuum casting is just one piece. There is no MOQ threshold — you can order anywhere from 1 to 100 parts depending on your project needs. This makes vacuum casting ideal for producing single samples, replacement parts, or niche products where larger production runs are not economically viable.
QHow much does a single vacuum cast part cost?
A single vacuum cast part typically costs around $550, which includes the master pattern, silicone mold, and one cast part. As quantity increases, the mold cost is amortized across more parts, dropping the per-unit cost to approximately $25 per part at 100 units. The exact cost depends on part size, material selection, and finishing requirements.
QWhat is the lead time for small batch vacuum casting?
Small batch vacuum casting has a lead time of 5–7 days for the first batch of parts. This includes master pattern creation, silicone mold making, and casting. Larger batches of 50–100 parts typically take 10–15 days as additional molds and casting cycles are required.
QCan I order more parts later if I need them?
Yes, you can place repeat orders using the same silicone mold if it is still within its 20–30 copy lifespan. We store molds for up to 6 months for repeat orders, so you can order additional parts without paying mold setup costs again. If the mold has degraded, a new mold can be created from the stored master pattern.
QHow do you ensure quality consistency across small batch parts?
For small batch orders of 1–100 parts, we perform 100% inspection rather than statistical sampling. Every part undergoes full dimensional inspection, visual surface check, and material verification. Our ISO 9001:2015 certified quality system ensures consistent results across the entire batch.
QHow are small batch parts packaged and shipped?
Small batch parts are individually packaged in protective bags with foam inserts to prevent damage during transit. We ship worldwide via DHL, FedEx, or UPS with typical delivery times of 3–5 business days. Each shipment includes a packing list and inspection report for your records.
Small Batch Vacuum Casting Applications
From custom samples to market test units, small batch vacuum casting serves a wide range of low-volume manufacturing needs.
Custom Samples
Production-quality samples for client presentations and trade shows
Replacement Parts
Discontinued or hard-to-find replacement components
Niche Products
Low-volume specialty products for limited markets
Limited Editions
Collectibles, art pieces, and numbered editions
Prototyping Batches
Functional prototype batches for testing and validation
Market Test Units
Pre-production units for market testing and user feedback
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Learn MoreStart Your Small Batch Vacuum Casting Project
Upload your CAD files and get a free small batch vacuum casting quote within 24 hours. No minimum order, 5–7 day turnaround, 20+ material options, and ISO 9001 certified quality. Our engineers provide DFM feedback and material recommendations at no cost.