How to Reduce Vacuum Casting Costs

Vacuum casting, a popular method for producing high-quality prototypes and low-volume production, has become an essential tool for designers and engineers.

The magic lies in its ability to replicate intricate designs and the potential for cost optimization. This article explains practical steps to reduce vacuum casting costs.

Understanding the Vacuum Casting Process

A 3D-printed master model is placed into a container and covered with liquid silicone rubber. Then, it’s put into a vacuum chamber, creating a detailed mold.

Liquid material is poured into the mold cavity. The mold is then placed under vacuum to remove any air bubbles, and the material is left to harden. Finally, the mold is opened, and the replica of the mold is removed. This process can be repeated about 30 times per mold, quickly and easily creating parts.

Material Selection

Different casting resins have varied costs. The trick is to understand your design’s functional requirements and match them to an appropriate resin. Sometimes, a less expensive resin can offer the same durability and aesthetics you aim for, significantly cutting down costs.

Minimize Complex Designs

While impressive, intricate details can increase costs. Designing parts with unnecessary complexities might require specialized molds or additional processing steps, increasing expenses.

Always ask: is this detail essential for function or aesthetics? If not, consider simplifying.

Optimize Wall Thickness

Uniform wall thickness prevents defects like warping or shrinkage. Additionally, a design with consistent wall thickness uses material efficiently. Avoiding overly thick sections saves on material costs and reduces curing times, further optimizing the production process.

The standard minimum wall thickness is 0.5 mm, but that depends on the part’s material and geometry.

Reduce Waste with Effective Mold Design

An intelligently designed mold can substantially cut down waste.

For instance, multi-cavity molds allow the production of multiple parts simultaneously, maximizing yield. Designing molds that are easy to fill and extract from also reduces the chances of producing faulty parts, ensuring that every ounce of resin is put to good use.

Take Advantage of Economy of Scale

While vacuum casting is often used for low-volume production, this doesn’t mean you can’t capitalize on bulk production. Ordering larger quantities can significantly reduce per-unit costs.

However, strike a balance – you don’t want to end up with an inventory that outweighs demand.

Prototype and Test 

Before diving headfirst into a full production run, prototype!

It might seem like an extra upfront cost, but this step can identify design flaws or process inefficiencies that could prove much more costly if caught in the production phase. Iterative testing allows tweaks and refinements, ensuring the final product is both high-quality and cost-effective.

Partner with the Right Manufacturer

Partnering with the proper manufacturer cannot be overstated in your quest for cost-effective vacuum casting.

At MakerVerse, we’re experienced with vacuum casting. Our expert team can provide technical assistance, ensuring your designs are optimized for the casting process. Moreover, with a vetted supply chain, we offer competitive prices.