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Looking to turn your prototype ideas into reality quickly and accurately? Super Ingenuity offers industry-leading custom vacuum casting services designed to deliver high-quality, low-volume plastic parts with exceptional detail and consistency.
Whether you’re developing a single prototype or preparing for small-batch production, our vacuum casting solutions ensure speed, precision, and repeatability.
Vacuum casting—also known as urethane casting or vacuum form casting—is a proven method for producing functional plastic prototypes using silicone molds. This process is ideal for:
Low-volume production (10–100 units)
Functional testing
Visual and functional prototyping
Bridge manufacturing before injection molding
Highly accurate, repeatable parts
Wide range of materials including flexible & rigid polyurethanes
Fast turnaround (as fast as 5 days)
Cost-effective alternative to injection molding
At Super Ingenuity, we combine cutting-edge casting technology with rigorous quality control to meet your specific product requirements.
Urethane Vacuum Casting for functional prototypes
Low-volume production with short lead times
Custom vacuum casting for prototypes of all shapes and finishes
Rapid quoting and DFM feedback
Dimensional accuracy: ±0.2 mm
Surface textures: Glossy, matte, soft-touch, or custom
Color matching and painting available
Our precision vacuum casting solutions are trusted by product developers in:
Consumer electronics
Automotive & EV components
Medical device housings
Robotics & industrial enclosures
This process bridges the gap between early-stage design and full-scale production — without breaking your budget or timeline.
Super Ingenuity stands out as your ideal vacuum casting partner thanks to:
🏭 Production-grade results without injection molding lead times
📦 One-stop service from design review to delivery
🔍 100% inspection for every batch
🌎 Global support and on-time delivery across the world
“We don’t just cast — we engineer confidence into every prototype.”
Vacuum Molding is an innovative process using silicone molds to replicate detailed prototypes quickly and affordably. It’s especially beneficial when you need:
Small batch production for testing
Low initial investment compared to injection molding
Quick turnaround times (often within days!)
| Feature | Vacuum Casting | CNC Machining | Injection Molding |
|---|---|---|---|
| Cost for Small Batches | ✅ Low | ❌ High | ❌ High |
| Detail Reproduction | ✅ Excellent | ✅ Good | ✅ Excellent |
| Lead Time | ✅ Short (5–10 days) | ❌ Longer (10–15 days) | ❌ Long (20+ days) |
| Material Variety | ✅ Wide Range | ✅ Limited | ✅ Limited |
💡 Key Insight: Vacuum Molding is the ideal method when you need functional prototypes without the prohibitive costs of traditional manufacturing.
Vacuum Molding excels in achieving remarkable fidelity to master patterns. Here’s how it maintains tight tolerances and flawless surfaces:
You can choose from a variety of polyurethane resins mimicking:
ABS
Polypropylene (PP)
Rubber-like materials
Each resin offers specific mechanical properties, ensuring your prototype matches your final product in strength, flexibility, or heat resistance.
Dimensional tolerances: ±0.2–0.5%
Wall thickness: as low as 1.5 mm
Excellent surface finish with minimal post-processing
Vacuum Molding allows automotive manufacturers to quickly create:
Dashboard assemblies
Lighting components
Under-the-hood parts for fit and function testing
From housings to precision connectors, custom Vacuum Molding services cater to the semiconductor and electronics sectors, ensuring prototypes meet exacting industry standards.
Explore our Five-Axis CNC Machining Services for complex, precision-milled prototypes.
Visit our Technical Article Hub to learn how vacuum casting compares with injection molding.
Return to our Homepage for a full overview of services.
Vacuum Molding is a versatile manufacturing process used to create high-quality prototypes and low-volume production parts. The process begins with creating a master model, often using 3D printing. A silicone mold is then formed around the model, and once the mold is cured, it’s cut open to remove the master. The mold is placed in a vacuum chamber, where liquid resin is poured into it. The vacuum removes air bubbles and ensures accurate filling. After curing, the parts are removed, trimmed, and finished. The entire process typically takes 7-10 days, depending on the complexity and volume of the order.
For more information, you can refer to authoritative resources like:
A:Vacuum casting is a rapid manufacturing process that uses silicone molds and urethane resins to produce highly accurate plastic prototypes. After creating a master model (often via CNC or 3D printing), a mold is formed and used to cast multiple identical parts under vacuum conditions to eliminate bubbles and ensure quality.
A:We offer turnarounds as fast as 5–7 business days, depending on part complexity and volume. Once your master model is approved, our team can move quickly into mold making and production — perfect for tight product development cycles.
A:
We support a wide range of urethane materials, including:
Rigid plastics (ABS-like, PC-like)
Flexible rubbers (Shore A range)
Transparent or tinted resins
Heat- or UV-resistant grades
Let us know your application needs and we’ll match the best-fit material.
A:Yes! Vacuum casted parts are ideal for functional and fit testing, especially when you need production-like properties without full injection molding costs. They’re commonly used for assembly validation, mechanical testing, and early field trials.
A:Vacuum casting is most cost-effective for quantities between 5 and 100 units. It’s perfect for prototyping, market testing, or bridge production. Need a few parts or a few hundred? We’ve got you covered.
A:Just click here or send us your CAD files and basic requirements. Our engineering team will review your design, recommend materials, and send you a quote within 24 hours — no strings attached.
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