Vacuum Casting — Production-Quality Small Batches in Polyurethane
When 3D printing isn't cosmetic enough and injection moulding isn't justified, vacuum casting delivers 1–50 polyurethane parts that look and feel like injection moulded production. Forge Labs casts cosmetic-grade prototypes, multi-material over-moulds and rubber elastomer parts in our Sydney workshops.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why vacuum casting beats both prototyping and tooling
When you need 5–50 cosmetic-grade parts and you need them next week.
1 to 50 Identical Parts
The fastest route to small batches of polyurethane parts that look and feel like injection moulded production.
Production-Like Polymers
Polyurethanes mimicking ABS, PP, rubber and clear PC — full range of Shore hardnesses and optical clarity.
No Tooling Investment
Silicone moulds cost a fraction of aluminium tooling and are ready in 7–10 days from a master pattern.
Over-Mould & Insert Capable
Multi-material parts, soft-touch grips, insert-cast threaded bushings and embedded electronics all possible.
Cosmetic-Grade Finish
Mould-replicated SLA-pattern surfaces deliver cosmetic finish equivalent to T1 injection moulded parts.
Our Workflow
From CAD to demoulded polyurethane part
Master pattern
We print an SLA master to your CAD with crisp surface finish and tight tolerances. This becomes the mould pattern.
Silicone mould
The master is suspended in a frame and platinum-cure silicone is poured around it under vacuum. Cured mould is split and the master removed.
Vacuum cast
Two-part polyurethane is mixed and degassed, poured into the silicone mould under vacuum, then oven-cured.
Demould, trim, finish
Parts are demoulded, gates trimmed and finished — paint, prime, clear-coat or assembly as required.
What we deliver
Silicone moulding with cosmetic-grade results
SLA master · Platinum silicone · Vacuum-degassed polyurethane
Vacuum casting is built around an SLA master pattern that defines surface finish and dimensional accuracy. The pattern is encased in platinum-cure silicone under vacuum to capture every detail, then two-part polyurethane is poured into the cured silicone mould — again under vacuum to eliminate bubbles — and oven cured. The result is cosmetic-grade parts in production-like polymer, ready for paint, pad-printing or assembly.
- SLA master pattern with crisp surface finish and tight tolerances
- Platinum-cure silicone moulds for ~15–25 part runs per mould
- Rigid (ABS-like, PP-like), flexible (Shore 30A–80A), clear and FR polyurethanes
- Multi-shot over-moulding for soft-touch grips on rigid bodies
- Insert-cast brass bushings, magnets and embedded electronics
- In-house paint, pad-print, clear-coat and assembly finishing
Materials
Polyurethanes for every prototype need
From rigid ABS-like consumer prototypes to Shore 30A rubber gaskets and optically-clear lens prototypes.
ABS-Like PU (Hei-Cast 8150)
RigidTough, paintable polyurethane that looks and behaves like injection-moulded ABS. The default for consumer prototypes.
PP-Like PU
FlexiblePolypropylene-like polyurethane for caps, closures and parts that need a hint of flex and chemical resistance.
Clear PU
OpticalOptically clear polyurethane for prototype lenses, light guides and transparent housings.
Rubber PU (Shore 30A–80A)
SoftFull range of rubber-like PUs for over-moulded grips, seals, gaskets and elastomeric components.
High-Temp PU
HeatPolyurethane with ~120 °C service temperature for under-bonnet and heated-environment prototypes.
Flame-Retardant PU
FRUL94 V-0 polyurethane for electrical-housing prototypes that need to pass flammability spec at trial stage.
Industries we serve
Where vacuum casting earns its keep
When you need 5–50 cosmetic-grade parts faster and cheaper than any other process can deliver.
Trade Show Samples
10–50 cosmetic-grade product samples for trade shows, sales demos and investor presentations.
Medical Trial Quantities
Small-batch quantities of device housings for clinical trials before committing to bridge or production tooling.
Film & TV Props
Multiple identical prop copies in rubber or rigid PU — typically 5–20 hero pieces with safety duplicates.
User Testing
Multiple physical samples for user-testing sessions, ergonomic studies and focus groups before tooling commitment.
Automotive Interior Trim
Multi-colour, multi-material interior trim prototypes with over-moulded soft-touch areas.
Design Verification
Final-finish design verification copies — what the part will look like, feel like and behave like in users' hands.
Showcase
Recent vacuum casting work
Vacuum cast polyurethane consumer product — painted and pad-printed.
SLA master pattern, used to produce the silicone mould.
Multi-material over-moulded prototype — rigid body, soft-touch grip.
FAQ
Frequently asked questions
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.