Industrial Vacuum Casting Services.

High-Fidelity Polyurethane Parts. Custom Molded Urethane Production.

Transition seamlessly from rapid prototyping to bridge production. Crenodez provides top-tier vacuum casting services through an expertly managed manufacturing network. Designed for engineers and procurement managers seeking low-volume plastic manufacturing (10 to 50+ parts), our process delivers custom molded urethane parts with the mechanical strength, color precision, and surface finish of final injection-molded components—without the upfront cost or lead time of steel tooling.

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What is Precision Polyurethane Casting?

Vacuum casting—often referred to as urethane casting—is the premier silicone rapid prototyping method for duplicating high-fidelity plastic and rubber components. The process involves creating a high-precision silicone mold around a physical master pattern inside a controlled vacuum chamber. By extracting all ambient air molecules during atmospheric degassing, liquid polyurethane resins flow flawlessly into complex geometries. This makes vacuum casting prototyping the ultimate solution for pre-clinical trials, functional validation, and low-volume market releases.

Bridge Production

Engineered Beyond Standard Prototypes

While 3D printing is excellent for form verification, our silicone prototyping solves the ultimate challenge of functional testing: material realism and cosmetic perfection.

Flawless Injection-Molded Surface Quality: Cast parts exit the mold with exceptional surface smoothness and zero visible layer boundaries, ready for immediate assembly or consumer presentation.
Advanced Overmolding & Insert Molding: Seamlessly encapsulate threaded brass inserts, metallic fasteners, or multi-material elastomeric grips into a single monolithic component.
Complex Geometric Freedom: Highly flexible silicone molds allow us to release parts with severe undercuts, reverse drafts, and variable wall thicknesses that would trap or break rigid steel tools.

ISO 9001 Certified

The End-to-End Vacuum Casting Workflow

1. The Master Pattern

We fabricate a high-resolution master pattern using our advanced large-format SLA 3D Printing Services. The pattern is meticulously hand-polished to achieve your exact requested surface texture (matte, gloss, or custom texturing).

2. Silicone Mold Vulcanization

The master pattern is suspended inside a casting box, and high-quality, engineering-grade RTV liquid silicone is poured around it. It cures in a thermal oven, creating a highly durable, flexible split-mold negative.

3. Degassing & Resin Pouring

The master pattern is removed. The silicone mold is clamped and placed inside an industrial vacuum chamber. Two-part polyurethane resin is mixed and poured under deep vacuum to guarantee zero internal air bubbles or voids.

4. Thermal Post-Curing

The filled mold enters a thermal envelope to solidify completely. Once cured, components are extracted, gates are trimmed, and parts undergo final inspection for dimensional accuracy.

Material Library

Production-Grade Polyurethane Materials

ABS-Like Resins: Offering an optimal balance of structural rigidity and impact toughness. Perfect for electronics enclosures and rugged industrial connector housings.
PC/PMMA-Like (Optical Clarity): Specialized transparent resins with excellent light transmission. Ideal for light pipes, lens assemblies, and fluid visualization devices.

PP/Nylon-Like (High Flexibility): Highly ductile resins engineered with superior elongation-at-break. Perfect for snap-fit panels and structural brackets.
Elastomers & Rubbers (Shore 30A to 90A): Flexible polyurethanes designed to mimic specialized rubbers. The definitive choice for manufacturing a functional rubber keypad prototype, silicone keypad prototype, custom seals, and ergonomic handles.

Proven Sectors

Validated Across High-Stakes Sectors

Automotive & Electric Vehicles

Complex air ducting assemblies, texturized interior dashboard trim panels, and functional enclosures for EV battery housing validation.

Medical Devices & Healthcare

Small-batch manufacturing of biocompatible enclosures, pre-clinical ergonomic test models, and clear fluid-flow housings.

Aerospace & Defence

Lightweight, flame-retardant interior cabin components and ruggedized communication housings.

IoT & Automation

Precision casting of robust sensor housings and modular industrial connectors designed for harsh environments.

Consumer Electronics & Home Appliances

Vacuum casting 3D printing hybrid workflows to produce showroom-ready bezels, custom buttons, and appliance housings prior to mass production.

Frequently Asked Questions

Q: What is the typical life expectancy of a silicone mold?

A: A standard silicone mold typically yields between 15 to 25 premium parts before dimensional tolerances begin to drift due to the chemical reaction of the curing resins. For larger batches, we seamlessly replicate the master pattern to cut additional silicone tools.

Q: What dimensional tolerances can be achieved with vacuum casting?

A: Our industrial casting process reliably holds general tolerances of ±0.15mm for the first few parts, moving to ±0.2mm as the silicone mold expands slightly over subsequent runs.

Q: Can you match specific color profiles like RAL or Pantone?

A: Yes. We tint the base polyurethane liquid resins prior to casting to achieve exact Pantone, RAL, or custom physical sample color matches. The color is completely integrated throughout the part.

Q: Can I get rubber and rigid plastic in the same part?

A: Absolutely. We offer overmolding services, allowing us to cast a rigid ABS-like inner core and overmold it with a soft, rubber-like elastomer for ergonomic grips or custom seals.

Q: Is vacuum casting cheaper than injection molding?

A: For low volumes (10 to 50 parts), yes. Vacuum casting eliminates the tens of thousands of dollars required to machine steel injection molds, making it the most cost-effective bridge tooling solution available.

Transitioning from low volume to mass scale? Compare this process with our high-volume Injection Moulding or sheet-based Vacuum Forming, or visit our primary Forming & Tooling Hub.