Vacuum casting

vacuum casted car's front grill

Vacuum Casting

Vacuum casting option for small lot production

INAC’s vacuum casting service supports small lot production from the development stage. We handle sizes up to approximately the scale of a car’s front grill, demonstrating capability for large automotive components. Most vacuum cast parts are produced in single colors, but INAC has developed technology that enables multicolor casting including two-color and three-color production within a single molding process.

Vacuum Casting Process and Advantages
Vacuum casting uses a master model to create a mold from silicone rubber. Resin material is then poured into the rubber mold to manufacture parts. Unlike injection molding that requires expensive metal tooling, vacuum casting with silicone rubber molds enables the manufacture of dozens of parts in a short period once a master model is available. This silicone rubber mold can be reused to make prototypes of various materials, providing flexibility in material selection.

Abundant Material Options
INAC offers extensive material choices for vacuum casting including ABS equivalent, PP equivalent, acrylic equivalent, elastomer equivalent, silicone, heat-resistant resin, and flame-retardant resin. Glass fiber can also be added to materials for enhanced strength properties. Different material insert casting is possible, allowing combination of multiple material types within a single component.

Quick Delivery Through In-House Integration
INAC manufactures vacuum casting products faster by producing master models in-house using stereolithography that can create prototype models in short timeframes. This integration of 3D printing and vacuum casting streamlines the production workflow and reduces overall lead times. Vacuum casting offers high cost performance when manufacturing several pieces, making it ideal for prototyping and small production runs.

Multicolor and Transparent Casting Capabilities
The front grill sample demonstrates simultaneous multicolor vacuum casting, showcasing INAC’s unique method for producing components with multiple colors in a single casting operation. Colored casting enables toning in accordance with color samples, while transparent casting provides clear visibility for design verification and visual presentations.

Applications for Design and Development
This vacuum casting capability is particularly valuable during product development stages where quick iterations and material testing are required without the time and expense of production tooling.

Please feel free to contact us.
Our experienced designers provide support from concept through prototype completion.

Multicolor casting​

Multicolor casting

Colored casting​

Colored casting

Transparent casting​

Transparent casting

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STEP5: Quality Assurance and Precision Inspection

A quality inspection is performed. At INAC, where quality comes first, we use CMMs, gauges, and other equipment for precision checks.

STEP4: Post-Processing and Finishing

Finishing is done by removing the supports, polishing, and applying transparency treatment. It is also possible to paint and apply plating to the formed product.

STEP3: UV-Laser Print Formation (SLA Process)

Output: The product is formed by irradiating the liquid with a laser beam of UV light and laminating it. The conditions of the external environment, such as room temperature and humidity, must be maintained.

STEP2: Model Program Generation and Support Adjustment

A program for model formation is created. Depending on the shape, it may be necessary to adjust the degree of tilt and the position of the supports.

STEP1: CAD File Submission

Upload your CAD to our online quoting platform.

STEP 3: Rendering and Scene Integration

We can also handle exterior modeling and interior structure design based on illustrations. After creating the 3D models, we can create a rendering to fit a scene. We can deliver images even if we do not proceed with production.

STEP 2: Detailed Design and 3D Modeling

Once the design is determined, drawings and 3D models will be created. The structure will be examined, taking into consideration not only the external design but also functionalities such as mating and sliding.

STEP 1: Initial Design Consultation

The first step is a meeting to discuss the project. Drawings are not required for this meeting. We will create a design from a sketch based on the overall image and concept that you have in mind.

STEP5: Quality Assurance and Inspection

We perform quality inspections. At INAC, where quality comes first, we use CMMs, gauges, and other equipment for precision checks.

STEP4: Post-Casting Finishing

Vacuum casting materials are cured and then taken out of the silicone rubber mold. Then we perform finishing such as deburring and gating, and they are made into finish products.

STEP3:Material Injuction

Liquid casting material is injected into the silicone rubber mold in a vacuum environment.　

STEP2: Mold Preparation

The silicone mold is cut open into a male and female mold, and the master model is removed.

STEP1: Mold Creation

The master model is fixed to a wooden frame and silicone is poured to create a mold.