Precision Vacuum Casting &
Pilot Batch
Production
Bridge the gap between design prototyping and high-volume mass production. At NextGen 3D Tech, we prominently feature industrial-grade Vacuum Casting (Silicone Molding) to deliver 20 to 50+ high-fidelity polyurethane parts with near-injection-molding physical properties, cosmetic finishes, and color accuracy.
Vacuum casting is a manufacturing process in which a liquid material is drawn into a silicone mold under vacuum, to create complex components. The process is similar to traditional injection moulding where it requires a mould tool with a part shaped cavity. Where injection mould tools are made from metal (steel, aluminium etc), vacuum casting uses soft silicone moulds.
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Cost-Effective Low-Volume Production
Produce 10 to 100+ parts without investing in costly injection molds, making vacuum casting ideal for pilot production and market testing.
Injection Molding-Like Quality
Silicone molds reproduce intricate details, textures, and surface finishes, creating parts that closely match injection-molded components.
Fast Turnaround
Receive production-quality parts in days rather than the weeks or months typically required for tooling and injection molding.
Wide Material Options
Choose from polyurethane resins that simulate ABS, PP, PC, rubber, transparent plastics, flame-retardant materials, and other engineering plastics.
Ideal for Pilot Production
Validate product design, conduct customer trials, and launch products with confidence before investing in mass-production tooling.
Excellent Surface Finish
Parts require minimal post-processing and can be supplied with painting, texture, silk screening, or custom finishing.
Flexible Design Changes
Unlike injection molds, silicone molds can be produced quickly, allowing design modifications with minimal cost and delay.
Reduce Development Risk
Test real production-like parts before committing to expensive steel tooling, reducing financial risk and accelerating product development.
How Does Vacuum Casting Work
Experience our 6-stage vacuum casting engineering process, moving fluidly from master model creation to final quality inspection.
Master Pattern
High-resolution SLA 3D print or CNC pattern is prepared and polished.
1 DaySilicone Casting
The master is suspended, and liquid silicone is cured under vacuum.
24 HoursMold Slicing
The cured silicone mold is sliced open, and the master pattern is removed.
2 HoursVacuum Pouring
Polyurethane resin is mixed, colored, poured under vacuum, and cured.
1-2 HoursDemolding & Cure
Cured parts are demolded, trimmed, and post-cured in ovens.
1 HourQuality Control
Dimensions, surface details, and color matching are verified before shipment.
Same DayMaster Pattern
High-resolution SLA 3D print or CNC pattern is prepared and polished.
1 DaySilicone Casting
The master is suspended, and liquid silicone is cured under vacuum.
24 HoursMold Slicing
The cured silicone mold is sliced open, and the master pattern is removed.
2 HoursVacuum Pouring
Polyurethane resin is mixed, colored, poured under vacuum, and cured.
1-2 HoursDemolding & Cure
Cured parts are demolded, trimmed, and post-cured in ovens.
1 HourQuality Control
Dimensions, surface details, and color matching are verified before shipment.
Same Day
Vacuum Casting For Every Sector
From 10-piece pre-production validation runs to 500-unit market-test batches, our polyurethane vacuum casting delivers injection-mould quality parts without the tooling cost — across every industry.
Automotive & EV
Pilot-run dashboard panels, bumper validation batches in ABS-like PU, EV battery cover prototypes, and painted interior trim sets for OEM approval.
Healthcare & Medical
Low-volume diagnostic device housings, ventilator panel batches, patient monitor enclosures, and biocompatible silicone over-molds for wearable sensors.
Consumer Electronics
Pre-production phone cases, remote control housings, transparent light guides, snap-fit battery covers, and soft-touch rubber grips for user testing.
Aerospace & Defence
Flame-retardant PU cabin panels, low-volume air ducting assemblies, cockpit switch housings, and non-conductive avionics enclosures.
Product Design & R&D
Painted cosmetic prototypes for investor pitches, user-study validation batches, crowdfunding sample runs, and pre-launch marketing display units.
Manufacturing & Tooling
Low-volume assembly jigs, go/no-go gauge batches, custom robotic arm grippers, alignment fixtures, and replacement machine covers in tough PU resins.
Electronics & Semiconductor
ESD-safe IC handling trays, low-volume PCB enclosures, custom connector housings, and heat-resistant sensor mounts cast in engineering-grade PU.
UAV & Robotics
Impact-resistant drone shell batches, custom payload brackets, camera gimbal housings, lightweight landing gear sets, and over-molded vibration dampeners.
Oil, Gas & Petrochemical
Chemical-resistant sensor enclosures, low-volume valve body covers, custom flange seals in flexible PU, and pilot-run downhole tool housings.
Marine & Hydraulics
Water-resistant pump housings, impeller test batches, custom marine-grade seal sets, and corrosion-proof instrument panel covers.
Energy & Power
Prototype battery enclosures, solar inverter housings, low-volume electrical junction covers, and UV-stable outdoor equipment panels.
Logistics & Packaging
Custom protective inserts, shock-absorbing transit trays, low-volume foam-lined cases, and branded packaging prototypes for product launches.
Pharma & Lab Equipment
Low-volume cartridge housings, custom reagent dispenser bodies, autoclavable silicone gaskets, and pilot-batch diagnostic kit enclosures.
Film, Props & Cosplay
Batch-run prop replicas, flexible silicone masks, armour component sets, custom helmet batches, and lightweight set decoration elements.
Education & Research
Low-volume lab equipment housings, custom sensor mounts, demonstration model batches, and functional teaching-aid component sets.
Space & Satellite
Lightweight satellite panel batches, payload bracket validation runs, thermal shield housing prototypes, and custom composite fitment sets.
Commitments That Protect You
Beyond technology, we offer peace of mind. Our foundation is built on trust, security, and unwavering support for every client.
100% IP Security
Dedicated Support
Fast Delivery
Capture accurate 3D data from existing components to recreate, modify, or optimize designs.
Explore Service
Transform digital designs into high-precision prototypes and functional parts with advanced additive manufacturing technologies.
Explore Service
Produce high-quality, low-volume parts with production-like finish, ideal for validation and market testing.
Explore Service
Scale seamlessly from prototype to volume manufacturing through injection molding, CNC machining, and production support.
Explore Service
Got Questions?
We Have Answers
Everything you need to know about our additive manufacturing processes, tolerances, and service capabilities. Can't find your answer? Reach out to our experts.
