What Materials Are Used In Vacuum Casting?

In vacuum casting, a variety of materials can be used to create prototypes or low-volume production parts. The choice of material depends on the desired properties, appearance, and functional requirements of the final product. Here are some commonly used materials in vacuum casting:

Polyurethane (PU) Resins: Polyurethane resins are widely used in vacuum casting due to their versatility and ability to simulate a range of thermoplastic properties. PU resins come in different formulations, offering options for rigid, flexible, transparent, or elastomeric parts. They can replicate the mechanical properties of materials such as ABS, polypropylene (PP), polycarbonate (PC), and more.

Epoxy Resins: Epoxy resins are a favored option for vacuum casting due to their exceptional dimensional stability, resistance to high temperatures, and robust mechanical properties. They are ideal for producing prototypes or components that demand high strength, resistance to chemicals, or thermal stability.

Silicone Rubber: Silicone rubber is utilized for crafting the molds in vacuum casting. Its flexibility and durability enable it to capture the complex details and undercuts of the master pattern. The reusability of silicone molds facilitates the efficient replication of parts.

Polypropylene (PP) Resins: Often utilized in vacuum casting, polypropylene resins mimic the characteristics of this widely-used thermoplastic. Replicas made from PP can demonstrate robust chemical resistance, a low density, and satisfactory mechanical properties.

Acrylic Resins: Employed in vacuum casting for producing transparent or semi-transparent components, acrylic resins provide clear visibility, strong impact resistance, and durability against the elements, ideal for uses that demand optical transparency or visual checks.

Rubber-Like Materials: Vacuum casting is capable of replicating materials similar to rubber, such as elastomers or flexible rubbers. These materials are known for their outstanding flexibility, resilience, and vibration-damping characteristics. They are frequently utilized in the production of gaskets, seals, grips, or any other application that necessitates a soft or cushioning element.

Specialty Resins: Vacuum casting can also employ specialty resins based on the specific needs of the project. Options include resins that are flame-retardant, resistant to high temperatures, electrically conductive, or other specialized formulations designed for unique applications.

It is crucial to recognize that material availability can differ between vacuum casting service providers. Each provider might have a range of materials that possess distinct properties and characteristics. Therefore, when opting for vacuum casting, consulting with the service provider to identify the material that best fits your project's requirements is recommended.

Surface Finishes for Vacuum Casting
Barana Rapid can build unique surface layers for your vacuum casting parts using a wide range of surface finishes. These finishes assist you in meeting the aesthetic, toughness, and chemical resistance needs of your products. We can provide the following surface finishes based on your material selection and part application:
	Name	Description
	Glossy	A grade finishes are made using a diamond buffing process and yield shiny and glossy surfaces on injection molded parts.
	Semi-glossy	Semi-glossyB-grade finishes employ coarse-grit sandpaper to create parts with a finish that is somewhat rougher than A-grade parts. Custom-molded plastic parts subjected to B-grade finishing exhibit a matte surface texture.
	Matte	C grade finishes use grit sanding stones to produce a rough, uneven surface. Injection plastic parts that undergo C grade finishing have a matte surface texture.
	Textured	D grade finishes use grit and dry glass beads or oxide to produce a very rough textured finish. Depending on the type of material used, products can have a satin or dull finish.

CNC turning is a precision machining process where a cutter removes material by making contact with a rotating workpiece. The machinery's movements are governed by computer instructions, guaranteeing precise and consistent outcomes.

CNC turning is distinct from CNC milling; in turning, the cutting tool rotates and approaches the fixed workpiece from various angles. The workpiece itself is rotated in a chuck during CNC turning, facilitating the creation of circular or tubular shapes. This method is especially adept at producing precise rounded surfaces that might be difficult to attain with CNC milling or alternative techniques.

A CNC lathe machine used for turning typically has a turret where the tooling is mounted. This turret can be programmed to execute specific movements and remove material from the raw materials, ultimately forming the desired 3D model or part.

Similar to CNC milling, CNC turning is suitable for both rapid prototyping and the production of end-use parts. Its precision and efficiency make it a valuable process for manufacturing components with round or tubular geometries.

By utilizing CNC turning, manufacturers can achieve high-quality results, optimize production time, and produce prototypes or final parts with accuracy and repeatability.

CNC turning as a subtractive manufacturing process where a stationary cutting tool removes material by making contact with the spinning workpiece to shape it according to the desired specifications.

In CNC turning, a blank bar of stock material is securely held in the chuck of the spindle and rotated along with the spindle itself. The cutting tool, which remains stationary, then removes material from the workpiece to create the desired shape. The movement of the machinery is precisely controlled by computer instructions, ensuring accuracy and repeatability in the manufacturing process.

CNC turning is particularly suited for creating round or tubular shapes and achieving highly accurate rounded surfaces. The rotational nature of the process allows for the creation of cylindrical components, such as shafts, cylinders, and other rotational symmetry parts, with excellent precision.

Our Low-Volume Manufacturing Processes
Barana Rapid has more than ten years of experience in small-batch manufacturing, an excellent team, and strong suppliers to meet all your small-batch manufacturing needs. Based on our many years of experience in small batch molding and excellent engineers, we will effectively execute all your projects involving small batch machining. This is due to the strong supply chain and advanced small-batch manufacturing equipment for different manufacturing technologies. You can rest assured that we will ensure the wholesale price is lower than that of our peers, strictly control the product quality standards, assist customers in optimizing the design, select the appropriate CNC processing technology, reduce costs, and achieve rapid mass production, to ensure that you will finally receive economic and high-precision products.
CNC Machining		High-speed, automated cutting can precisely form different shapes to reflect your designs on the metal or plastic material for low volume cnc machining.
Plastic Injection Molding		Plastic injection molding can turn thermoplastic materials into specific plastic parts, whether it is mass production or low volume production.
Sheet Metal Fabrication		Sheet metal fabrication is a subtractive manufacturing process that can be applied for low volume manufacturing and prototyping of metal parts.
Vacuum casting		Vacuum casting is a custom manufacturing method used for the production of small series of functional plastic parts.
Die Casting		Die casting is a manufacturing process in which molten metal is poured or forced into steel molds, allowing for small volume production of quality metal injection molded parts with low cost.
Aluminum Extrusion		Vacuum casting is a custom manufacturing method used for the production of small series of functional plastic parts.
3D Printing		We offer a wide variety of 3D printing services, such as SLA 3D printing (Stereolithography) and SLS 3D printing (Selective Laser Sintering). Our engineers and project managers will collaborate with you to confirm your CAD designs, product functions, dimensional tolerances, etc.

Comparatively, CNC milling involves the rotation of the cutting tool while the workpiece remains stationary, allowing for the creation of more complex shapes and features. CNC milling is typically used for producing parts with intricate geometries, such as slots, pockets, and complex 3D profiles.

Understanding the difference between CNC milling and CNC turning is valuable in determining the appropriate machining process based on the desired outcome and the specific requirements of the part or component.

If you're looking for further information on the distinctions between CNC milling and CNC turning, you can refer to the link you provided or explore additional resources that delve into the topic in more detail.

What Separates Barana Rapid’s Inspection Processes from the Rest?

Careful measurement, inspection and testing are necessary to ensure the conformance of your parts. We perform multiple inspections at every step of the product development journey, from incoming material verification to final 3D scanning. You will receive complete digital files and Certificates of Compliance so you can meet your own regulatory and performance goals.

An International Team with Unparalleled Experience

Quality inspection relies not only upon using advanced digital equipment but also having highly trained personnel with years of experience. As parts become more complex and tolerances more demanding for advanced applications, precision measurements conducted by professionals are the only way to ensure perfection.

Inspections and Review for Every Stage of Production

To ensure quality from start to finish, Barana Rapid provides the following inspection and review services:

Extensive incoming materials verification

Design for manufacturing reviews for all quotes provided

Contract reviews upon receipt of POs

First article and in-process inspections

Final inspections and testing with reports and certifications as required