Vacuum Casting

ZigiTech delivers precision vacuum casting and silicone molding services for rapid prototypes, functional testing, and low-volume production parts.

  • Silicone mold making and urethane casting from one factory workflow
  • Stable quality for engineering prototypes and bridge production
  • Fast quotation and responsive lead-time planning
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Vacuum casting prototype parts in multiple translucent colors
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urethane material options and finishes
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typical production days after DFM approval
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quality-controlled Manufacturing Service
Urethane vacuum casting samples arranged for quality review

Vacuum Casting

ZigiTech is fully capable of handling your vacuum casting and silicone molding needs. With years of hands-on manufacturing experience, we produce plastic parts to a reliable standard with practical cost control and fast turnaround.

Vacuum casting is an efficient method for rigid or flexible components and is ideal for high-quality prototypes, functional testing, concept validation, and display models. Urethane casting parts can be delivered in quantities from a few units up to hundreds based on your project stage.

As a machinery parts manufacturer and integrated Manufacturing Service partner, we support your project from data review to final part delivery. Contact us today for technical guidance and a fast quote.

Advantages of Vacuum Casting

Fast Turnaround

ZigiTech can deliver up to 20 parts within 15 days, depending on geometry complexity and order volume.

Affordability

Silicone molds are significantly more cost-efficient than hard tooling, making this route ideal for low-volume programs.

Capable of Producing Large Parts

With the right mold strategy and casting setup, vacuum casting supports large-format plastic components.

Superior Surface Finish

Vacuum degassing helps remove trapped air and preserves fine details for cleaner cosmetic surfaces.

Color Options

Pigments can be blended into the resin system to create a wide range of stable color appearances.

Repeatability

Each silicone mold can generally support around 20 repeat cycles with consistent part quality.

Your Manufacturing Partner from Prototype to Production

Whether you need one part or one thousand, our team provides the engineering support and quality control your program demands.
01

Start with a Quote

Upload your CAD files for instant pricing and lead time estimates.

Upload CAD files and project requirements.
02

Review DFM Analysis

Get expert feedback on manufacturability, cost drivers, and risk factors.

Review instant pricing and DFM guidance.
03

Approve & Produce

Confirm specifications and our team begins manufacturing your parts.

Approve manufacturing details before production starts.
04

Inspect & Ship

Every part is verified before packing and dispatch to your location.

Finished parts prepared for shipment.

What Is Vacuum Casting?

Vacuum casting is a manufacturing process that uses negative pressure to draw liquid resin into a silicone mold. Unlike injection molding, this method is optimized for rapid validation and short-run part delivery without hard tooling investment.

The workflow starts from a master pattern, typically produced by CNC machining or 3D printing. ZigiTech then builds a silicone mold around that master, cures it, and prepares it for repeat casting cycles with stable dimensional control.

After mold preparation, resin is poured and vacuum-assisted to remove trapped air. This helps capture fine details, reduce bubbles, and produce consistent surfaces for prototype and low-volume parts.

Vacuum cast plastic component used for prototype validation

Each cast part replicates the master geometry with high consistency. Once cured and demolded, the silicone tool can usually support around 20 cycles, making vacuum casting a practical choice for prototyping and small-batch Manufacturing Service needs.

Vacuum Casting Process

01

Master Building

The process begins with a master model created from your CAD data, usually by CNC machining or 3D printing. After dimensional and visual inspection, ZigiTech releases the master for silicone mold preparation.

02

Mold Making

Liquid silicone is poured around the master pattern and cured under controlled temperature conditions. After full curing, the mold is split along the planned line and the master is removed for casting setup.

03

Part Casting

Casting resin is poured into the mold cavity and vacuum-assisted to reproduce the original geometry with high accuracy. Depending on part geometry, one silicone mold typically supports around 20 repeat casts.

Vacuum Casting Technical Specifications

Typical Lead Time
Up to 20 parts in 15 days or less, depending on part complexity and order volume.
Dimensional Accuracy
±0.3% with a lower limit of ±0.3 mm for dimensions smaller than 100 mm.
Minimum Wall Thickness
A minimum wall thickness of 0.75 mm is required for mold filling. For best stability, we recommend 1.5 mm or above.
Maximum Part Dimensions
Part size is limited by vacuum chamber capacity (1900 x 900 x 750 mm) and product volume (maximum 10 liters).
Typical Quantities
Up to 25 copies per mold, depending on mold complexity and resin system selection.
Color & Finishing
Pigments can be blended into liquid polyurethane before casting, with optional custom painting and texture finishing.

Vacuum Casting FAQ

Urethane casting is usually more cost-efficient for prototypes and low-volume demand because it avoids expensive hard tooling while still delivering good surface quality and dimensional stability.
Yes. Vacuum casting can produce production-quality parts for selected use cases, especially housings, covers, and other non-load-bearing components in bridge and short-run programs.
Silicone molds have a limited service life, typically around 20 cycles depending on geometry and resin. We can retain or dispose of molds based on your project request, and master models can also be returned on demand.
Verified Client Feedback
Trusted by teams shipping precision parts under real production deadlines.

We needed anodized housings shipped overseas without cosmetic damage. The packing method was clearly thought through, and the appearance held up well.

Romain Lefevre Supply Chain Coordinator, French drone systems supplier

The quote came back with a lead time we could actually commit to internally. That matters more than hearing an aggressive number that slips later.

Brooke Nelson Commodity Manager, Canadian industrial controls OEM

On a short-run extrusion order, the communication separated confirmed details from open questions very clearly. That sounds basic, but not every supplier does it well.

Tom Becker Project Lead, German power electronics company

We have now used them on several prototype orders, and the experience has been repeatable. Quotes are structured, revisions are tracked, and boxes arrive in good shape.

Nina Rossi Purchasing Manager, Italian lab automation manufacturer

This was one of those jobs where we mainly needed the supplier not to create extra work. In that respect, Zigitech did very well.

Chris Walters Engineering Director, US industrial automation integrator

We started with prototype parts and later rolled into a small production batch, so handoff between stages mattered. The process stayed orderly instead of feeling like two separate vendors.

Rebecca Stone Program Manager, US mobility hardware company

The aluminum housings on our order had flatness requirements that were not especially forgiving. Incoming checks looked good, and the assembly team did not send anything back.

Koen Visser Mechanical Engineer, Dutch industrial electronics supplier

During a medical cart subsystem review, their comments were specific enough to improve the drawing without sending us into another long design cycle.

Rachel Moore Product Engineer, UK healthcare equipment brand

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