Vacuum Casting

In today’s competitive product development environment, speed and accuracy are crucial. At MXY Machining, we offer vacuum casting services that deliver high-quality prototypes and low-volume production parts with the feel, finish, and functionality of injection-molded components — without the long lead times and high tooling costs.

Whether you’re validating a design, testing functionality, or preparing for full-scale manufacturing, our vacuum cast solutions bridge the gap between prototype and production.

What is Vacuum Casting?

Vacuum casting, also known as urethane casting or silicone molding, is a manufacturing process used to produce high-quality plastic parts in small quantities. The process involves creating a master model (usually 3D printed or CNC machined), then using it to make a silicone mold. Liquid polyurethane or similar resin is poured into the mold under vacuum conditions to remove air bubbles and ensure a flawless finish.

Once the resin cures, the mold is opened to reveal a part that closely replicates the master — both in geometry and surface finish.

Key Advantages of Vacuum Casting at MXY Machining

Exceptional Surface Finish
Our vacuum-cast parts have smooth, detailed surfaces with minimal post-processing required — ideal for presentation models and functional prototypes.

Cost-Effective for Low Volumes
Perfect for 1 to 100+ units, vacuum cast avoids the high tooling costs associated with injection molding.

Fast Turnaround
Parts can be delivered in as little as 7–10 business days, helping you accelerate product development and testing.

Flexible Material Options
We offer a wide range of urethane resins that simulate everything from soft rubber to ABS, PP, and even glass-filled plastics.

 Highly Accurate Replication
Silicone molds capture intricate details, textures, and fine features with excellent dimensional consistency.

Color Matching & Finishing
Parts can be cast in a variety of colors, finishes (matte, gloss, transparent), and even overmolded or painted for final product appearance.

Applications of Vacuum Casting

Vacuum casting is one of the most versatile and cost-effective manufacturing methods for creating high-fidelity plastic parts in low volumes. At MXY Machining, our vacuum casting services are trusted by engineers, designers, and product developers across a wide range of industries. Here’s a closer look at how vacuum casting supports innovation, testing, and production in various sectors:

Product Design & Prototyping

Vacuum casting is ideal for producing presentation-quality prototypes that closely resemble final production parts in both form and finish. Whether you’re preparing for a product launch, an investor pitch, or consumer testing, our casting process delivers professional-grade parts that look and feel like injection-molded components.

• High-detail replicas with smooth surfaces and realistic textures
• Color and finish customization for real-world appearance
• Enables designers to iterate and validate aesthetic and ergonomic aspects before final tooling

Fit and Function Testing

Because vacuum-cast parts replicate the geometry and mechanical behavior of production-grade plastics, they are perfect for fit, form, and function testing.

• Validate assembly tolerances, snap fits, and hinged mechanisms
• Test components for movement, clearance, and compatibility
• Simulate final part behavior under light mechanical loads

Low-Volume Production

Vacuum casting bridges the gap between prototyping and full-scale manufacturing, making it ideal for short production runs when speed and flexibility matter.

• Produce 5 to 100+ units without investing in hard tooling
• Great for pilot runs, limited-edition products, and market testing
• Cost-effective for custom enclosures, control panels, consumer goods, and more

If you’re testing a new market, preparing for crowdfunding fulfillment, or need end-use parts quickly, vacuum cast offers production-grade quality without the high costs of injection molding.

Medical Devices

Vacuum casting plays a key role in the development of medical and healthcare devices, especially for projects that require precision, customization, and small-batch production.

• Casing prototypes, ergonomic handles, and display housings
• Test fixtures, jigs, and non-implantable components
• Smooth, sterilizable surfaces and materials that mimic production plastics

Our materials include biocompatible options for non-invasive applications and testing, ensuring that your prototypes meet functional and regulatory expectations in clinical environments.

At MXY Machining, we leverage vacuum casting to deliver reliable, production-quality parts for a wide range of applications — helping you move faster, make smarter design decisions, and bring your product to life with confidence.

Why Choose MXY Machining for Vacuum Casting?

 We create precision 3D printed or CNC-machined masters, ensuring perfect molds from the start.
Choose from dozens of urethane grades — clear, tinted, rigid, flexible, impact-resistant, or heat-resistant.

From Pantone color matching to polished, matte, or textured finishes, your parts can be tailored to exact aesthetic requirements.

Each silicone mold can produce 15–25 high-quality copies, giving you flexibility for short production runs

 Every part is inspected for dimensional accuracy, surface quality, and functional integrity.