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Pilot and Small Series

Vacuum casting

Mechanically usable models with attributes close to the finished serie part can be manufactured really 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 is embedded in  silicone and removed after of the silicone has hardened. The silicone mould reflects the model 1:1 with a 1/10 mm precision. Under a vacuum, the silicone mould is now filled with liquid resin to produce the finished cast.
Due to the mechanical wear and tear of the mould, an average of 15 to 20 casts can be produced from each one.
As these casts represent near perfect copies of the prototypes, they can be used to test technical parameteres of the future marketed product relatively accurately.

Advantages:

  • Fast (within 5 to 8 working days)
  • Small series of between one and a few hundred pieces possible
  • Use of latest casting materials that cover, a wide range of commercially available plastic, delivering functional parts with very similar attributes to the future injection-cast large series parts.  The material can be transparent, fibreglass-reinforced, dyed or soft, allowing the production of models, that accurately reflect the later series parts, particularly with regard 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 producing prototypes/models/serie parts from materials such as polystyrene, polycarbonate, or acrylic plastic boards. 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 in accordance with your product specifications, generally milling it from heat-resistant block material or aluminium. We can deep-draw parts in-house up to a size of 200x100x60 mm. For larger parts, we work 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 to the right shape can be completed in-house.

Advantages:

  • First pre-production parts with comparatively little effort
  • Small series of between one and a few hundred pieces possible
  • Different material thickness
Partsize:
  • Maximum 200 x 100 x 60 mm

Materials:
  • Polystyrene, Polycarbonate or Acrylics