Our Processes
Vacuum casting (VAC)
Our Processes
- Selective Laser Sintering (SLS)
- Powder Bed Fusion (MJF/SAF/HSS)
- Stereolithography (SLA)
- PolyJet (PJM) -EN
- CAD, manufacturing-oriented building component design & reverse engineering
- Measurement technology
- Metal casting
- Selective laser melting (SLM)
- RapidTooling (RT)
- CNC Machining
- Model making (MB)
- Vacuum casting (VAC)
- Fused Deposition Molding (FDM/FFF)
The vacuum casting process / polyurethane casting process enables you to produce near-series prototypes and small series. The master model is molded in silicone and then cast with polyurethane resins (PU).
The casting resin is selected according to the required material properties of the series material. This allows highly transparent parts, a combination of hard and soft materials, and inserts made of other materials to be produced.
The output of parts from the silicone molds, which measure a maximum of 800 x 700 x 700 mm, depends on the geometric complexity and limits the number of possible duplicates. Typical batch sizes are 5-100 parts.
Material data
A wide range of polyurethane resins from various manufacturers with a wide variety of material properties are available for silicone vacuum casting. The casting resins can be tailored to your requirements by adding color. Crystal-clear casting resins can also be processed.
Due to the wide variety of different materials, we are happy to offer you detailed advice.
- For rubber-like or TPE/TPU-like prototypes
- Selectable hardness between Shore A35 and A90
- Can be dyed for completely solid-colored components
- Similar to polypropylene (PP) or high-density polyethylene (HDPE)
- For housing components or cladding
- Can be dyed for completely dyed components
- Similar to acrylonitrile butadiene styrene copolymer (ABS)
- For functional prototypes, especially in the automotive industry
- Colored black for completely dyed components
- For thin-walled, transparent components
- Can be colored translucent
- Similar wear resistance to polyoxymethylene (POM) or glass-filled polyamide (PA-GF)
- 15% glass fiber content for functional prototypes
- Can be dyed for completely dyed components
- Similar to polyphenylene sulfide (PPS), polyaryletherketones (PEKK or PEEK)
- For high-temperature-resistant prototypes
- Can be dyed for completely dyed components
- Similar to polypropylene (PP)
- Higher elongation at break to obtain exemplary functional film hinges
- Can be dyed for completely dyed components
Materials
A wide range of polyurethane resins from various manufacturers with a wide variety of material properties are available for silicone vacuum casting. The casting resins can be tailored to your requirements by adding color. Crystal-clear casting resins can also be processed.
Due to the wide variety of different materials, we are happy to offer you detailed advice.
| Gießharze | Farbe | Eigenschaften | Anwendung |
|---|---|---|---|
| PN 9723 | dyeable | similar to TPU | Rubber-like prototypes, Shore A hardness adjustable |
| PR 777 | dyeable | similar to PP/HDPE | Housing parts, covers |
| PR 700 | dyeable | similar to ABS | automotive industry |
| PX 522 | transparent | – | Thin-walled transparent components, translucent and can be colored |
| PX 245 | dyeable | similar to POM/PA-GF | Functional prototypes, 15% glass fiber filled |
| PX 234 HT | dyeable | similar to PPS/PEEK | high-temperature-resistant prototypes |
| PX 205 | dyeable | similar to PP | Film hinge can be displayed |
Mechanical properties
| Material designation | PN9723 | PN9723 | PR777 | PR700 | PX522 | PX245 | PX234HT | PX205 |
|---|---|---|---|---|---|---|---|---|
| Hardness [Shore A/D1] | A 35 | A 90 | D1 75 | D1 80 | D1 85 | D1 80 | D1 70 | D1 70 |
| Flexural modulus [MPa] | 900 | 2300 | 2400 | 4500 | 1850 | 500 | ||
| Flexural strength [MPa] | 35 | 80 | 110 | 150 | 80 | 30 | ||
| Tensile modulus [MPa] | 1000 | 1800 | 2400 | 1020 | 530 | |||
| Tensile strength [MPa] | 1,5 | 10 | 32 | 60 | 66 | 85 | 40 | 25 |
| Elongation at break [%] | 35 | 13 | 7,5 | 3 | 13 | 100 | ||
| Impact resistance [kJ/mª] | 60 | 60 | 48 | 30 | 41 | k.B. | ||
| HDT [°C] | 70 | 80 | 94 | 94 | 85 | 92 | 190 | 55 |
References
Kevin is a laboratory assistant for simple tasks and for loading laboratory equipment. Among other things, the laboratory robot transports a plate with several reagents from device to device. Kevin was developed by the Fraunhofer Institute for continuous operation on weekends, holidays, and at night. The entire production and assembly of all cladding components for the first prototype was carried out by cirp. The housing was manufactured in two small series using vacuum casting, and the bumper in the lower section was cast from a soft material.
Copyright Fraunhofer Institute for Manufacturing Engineering and Automation IPA / cirp GmbH