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.
To meet diverse low-volume requirements, we also offer Reaction Injection Molding (RIM) for large impact-resistant enclosures, Fiber Reinforced Plastic (FRP) laminates for lightweight aerospace and automotive panels, Block Machining (CNC) for high-strength metallic/plastic housings, and Low Pressure Casting for casting alloy components.
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Flagship Vacuum
Casting
By casting polyurethane resins in custom silicone molds under vacuum, we eliminate air pockets and replicate fine textures, thread inserts, and colors with exceptional accuracy.
Full Suite of
Pilot Technologies
We round out our pilot capabilities with RIM for large automotive bumpers, FRP glass/carbon fiber layouts, CNC block machining for mechanical strength, and low pressure metal casting.
The Pilot Advantage
Experience industrial low-volume manufacturing. These 6 foundational pillars represent why industry leaders trust us with their pilot production and vacuum casting projects.
Silicone Tooling
High-quality silicone molds created from 3D printed master patterns.
PU Elastomers
Access a wide variety of polyurethane resins mimicking ABS, PMMA, rubber, or nylon.
Near-Molding Quality
Parts feature production-grade textures, colors, and mechanical properties.
Low Tooling Cost
Avoid expensive steel tooling with cost-effective silicone molds.
Reaction Injection
Reaction Injection Molding (RIM) mixing for large-scale structural parts.
Laminate Strength
Specialized hand-layup glass and carbon fiber reinforced plastic (FRP) layout.
Silicone Tooling
High-quality silicone molds created from 3D printed master patterns.
PU Elastomers
Access a wide variety of polyurethane resins mimicking ABS, PMMA, rubber, or nylon.
Near-Molding Quality
Parts feature production-grade textures, colors, and mechanical properties.
Low Tooling Cost
Avoid expensive steel tooling with cost-effective silicone molds.
Reaction Injection
Reaction Injection Molding (RIM) mixing for large-scale structural parts.
Laminate Strength
Specialized hand-layup glass and carbon fiber reinforced plastic (FRP) layout.
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 DayOur Featured Highlights
Pre-Production Functional Prototypes
High-Detail Polyurethane Castings
ABS & Rubber-Like Overmolding
Painted End-Use Enclosures
Short-Run Industrial Components
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
Zero Defect Policy
High-precision optical and laser scanning to reverse engineer parts, capture exact geometries, and digitize real-world objects flawlessly.
Explore Service
Stereolithography (SLA), SLS & FDM 3D printing for rapid high-resolution prototypes, transparent optics, and functional models.
Explore Service
Polyurethane vacuum casting and silicone tooling for low-volume production runs (10–500 units) without expensive hard tooling.
Explore Service
Multi-cavity plastic injection moulding and 5-axis CNC milling for high-volume end-use component manufacturing at scale.
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.
