Pilot and Small Series

Vacuum Casting

Mechanically usable models with attributes close to the finished serial part can be manufactured very quickly with the vacuum casting process. The main condition for vacuum casting is the availability of a master model. After the surface finish, the model will be embedded in Silicon and removed after hardening of the silicon. The silicon mould reflects the model 1:1 with a 1/10 mm precision. Under a vacuum, the silicon mould is now filled with liquid resin with the result of the finished cast.

Due to mechanical wear and tear of the mould, an average of 15 to 20 casts can be produced from one mould.

As these casts represent near perfect copies of the prototypes, they can be used to test technical parametres of the future marketed product relatively accurate.

Advantages:

  • fast (within 5 to 8 working days)
  • Small series of one to several hundred pieces possible
  • Usage of newest casting products, covering a large area of commercially available plastic, delivering functional parts with very similar attributes to the future injection cast large series parts. Material can be transparent, glass fibre strengthened, dyed or soft, allowing the production of series accurate models, particularly in regards to the surface after process.

Machine:
  • 5 casting machines in various sizes

Materials:
  • all common PU materials

Deep Drawing

Deep Drawing is a process for the production of prototypes/models/serial parts of materials such as plastic boards made from polystyrene, polycarbonate or acrylics. In this process, the material is pulled over or pushed into a deep drawing mould by means of heat and vacuum.

We construct a deep drawing mould according to your product specifications and generally mill it from heat resistant block material or aluminium. We can deep draw parts in house up to a size of 200x100x60mm. For larger parts, we cooperate with external partners.

Deep drawing is especially suitable for small to medium sized series for parts with appropiate dimensons. Any trimming of your deep drawn items into the right shape can be completed in house.

Advantages:

  • first pre-production with comparatively little effort
  • Small series of one to several hundred pieces possible
  • different material thickness

Partsize:
  • maximum 200 x 100 x 60 mm

Materials:
  • Polystyrene, Polycarbonate or Acrylics