Industrial-Grade Vacuum Casting: The Bridge to Production
Replicate production-quality parts with REBAN’s high-fidelity Vacuum Casting services. Using premium Polyurethane (PU) resins, we deliver small-batch runs that mimic the mechanical, thermal, and aesthetic properties of injection-molded plastics—without the high cost of steel tooling.
Overview
Vacuum Casting at REBAN is the bridge between rapid prototyping and mass production. Our process utilizes advanced Polyurethane (PU) Resins to achieve complex geometries with “molded-in” properties. We specialize in replicating the molecular behavior of engineering plastics—such as ABS, PC, and PMMA—allowing for seamless transition to injection molding or high-performance deployment in the field.
1. Engineering-Grade Thermoplastic Mimics
These resins are formulated to replicate the stress-strain curves and impact resistance of traditional injection-molded plastics.
ABS-Like Polyurethane: The industry workhorse. Formulated for high impact strength and excellent machinability. Ideal for electronic housings and consumer product enclosures.
PC-Like (Water Clear) Resins: High-optical-clarity polymers with UV stability. These resins mimic Polycarbonate, offering high light transmission and heat deflection temperatures (HDT) for lenses and light pipes.
PP/PE-Like Elastomers: Semi-rigid resins that provide the “snap-fit” capability and fatigue resistance of Polypropylene. Perfect for living hinges and automotive clips.
Glass-Filled / Reinforced PU: Infused with micro-glass fibers to increase flexural modulus and dimensional stability, simulating glass-reinforced nylon for structural components.
2. Specialized High-Performance Resins
Advanced chemistries designed for extreme environments where standard polymers fail.
High-Temperature & Functional Resin Library
| Resin Series | Target Mimic | HDT (at 0.45 MPa) | Tensile Modulus | Engineering Logic & Industrial Use |
|---|---|---|---|---|
| HT-Thermal Pro | PEEK / PPS-like | 180°C – 220°C | 3,800 MPa | Extreme Heat: Maintains structural rigidity for under-hood automotive manifolds. |
| FR-V0 Shield | ABS/PC Flame Retardant | 95°C | 2,400 MPa | Safety Compliance: UL94-V0 and FAR 25.853 rated; self-extinguishing for EV batteries. |
| ESD-Static Dissipative | Anti-Static POM | 85°C | 2,200 MPa | Electronics Protection: Surface resistivity 10^6–10^9 \Omega; for semiconductor jigs. |
| Bio-Class VI | Medical PC / PP | 80°C | 2,100 MPa | Biocompatible: ISO 10993 compliant; supports Gamma/EtO sterilization for surgical tools. |
| Impact-Max | Nylon 66 Mimic | 110°C | 2,800 MPa | Fracture Toughness: Exceptional energy absorption for power tool housings. |
| Optic-Clear UV | PMMA / PC Mimic | 105°C | 2,300 MPa | Zero Haze: 92% light transmission; UV-stable for light pipes and optical sensors. |
| Nano-Reinforced | 30% GF-Nylon Mimic | 150°C | 5,500 MPa | Ultra-Stiff: Replaces aluminum in structural drone frames and inspection jigs. |
3. Industrial Elastomers & Overmolding
Vacuum casting is the premier method for creating rubber-like parts with specific tactile and damping properties.
Multi-Shore A Resins: We offer a spectrum of shore hardness from 10A (very soft/gel-like) to 90A (hard rubber). Used for gaskets, seals, and vibration isolators.
Overmolding Chemistry: Specialized resins designed to chemically bond to rigid inserts or secondary cast parts. This allows for the production of ergonomic grips and multi-material assemblies.
High-Tear Strength Silicone: Used for complex undercuts and “flexible-tooling” masters, ensuring that even the most intricate geometries can be de-molded without deformation.
4. Aesthetics & Finishing Additives
The chemical agents and pigments used to achieve “out-of-the-mold” perfection.
Integral Color Pigments: Masterbatch pigments are mixed into the liquid resin under vacuum to ensure 100% color saturation throughout the part (Pantone/RAL matched).
UV Inhibitors: Chemical stabilizers added to clear resins to prevent yellowing or “chalking” when parts are exposed to sunlight or outdoor environments.
EMC/RFI Shielding: Conductive fillers (Nickel or Silver-coated copper) can be integrated into the resin or applied as a secondary coating to provide electromagnetic interference protection.
Texture Replication: Through our master-pattern finishing, we can replicate VDI-3400, Mold-Tech, or high-gloss (SPI-A1) textures directly into the silicone tool.
Material Compatibility & Application Guide
| Industry Application | Recommended Resin Match | Selection Logic (Engineering Rationale) | Performance Impact |
|---|---|---|---|
| Consumer Technology | Toughened ABS-like PU | High energy absorption during 1.5m drop-testing protocols. | Zero-crack reliability; Premium “retail-ready” tactile feel. |
| Fluid Power & HVAC | HT-Structural (GF-Infilled) | Low moisture absorption and high hydrolytic stability at 150°C+. | Maintains airtight seals under continuous pressure and heat. |
| Automotive Snap-Fits | Semi-Rigid PP-like PU | Yield strain >15% allows for repeated interference fits without whitening. | Zero clip failure; Prevents rattling/NVH in interior assemblies. |
| Wearable Technology | Skin-Safe Elastomer (Shore A) | Hypoallergenic formulation resistant to skin oils, sweat, and UV. | Long-term biocompatibility; Prevents material degradation. |
| Optoelectronics | Water-Clear PC-like (UV-Stable) | Zero micro-porosity ensures no light scattering or internal haze. | Crystal-clear signal for IR/Optical sensors and lenses. |
| Precision Jigs & Fixtures | Reinforced 90D PU (GF Mimic) | High flexural modulus ensures dimensional repeatability under load. | Maintains ±0.1mm tolerance over 1,000+ assembly cycles. |
| Submersible Housing | Hydrophobic IP68-Grade PU | Cross-linked polymer structure prevents osmosis at high depths. | Watertight integrity for underwater sensors and enclosures. |
| Robotic End-Effectors | Tear-Resistant 70A Elastomer | High coefficient of friction (CoF) for secure and rapid part handling. | Prevents slippage during high-speed pick-and-place operations. |
Engineering the Perfect Prototype
At REBAN, we treat Vacuum Casting as a precise science. Every pour is conducted in a controlled vacuum environment to eliminate micro-porosity and ensure the structural homogeneity of your parts. Whether you need a single visual masterpiece or a small-batch production run of 50 units, our materials are validated to perform.
Our Quality Commitment
Degassing Excellence: 100% bubble-free parts through multi-stage vacuum processing.
Dimensional Accuracy: Tight tolerances (typically ±0.1mm per 100mm) maintained through calibrated oven curing.
Master Pattern Precision: SLA/CNC master patterns are hand-finished to ensure the tool captures every micron of detail.