Vacuum Casting Hyderabad
Tek4s provides high-quality vacuum casting services for rapid prototyping and low-volume production. Using precision silicone molds and advanced polyurethane materials, we replicate production-grade plastic parts with excellent surface finish and dimensional accuracy. Ideal for visual models, functional testing, and bridge tooling, Tek4s’ vacuum casting ensures cost-effective and fast turnaround without compromising on detail or durability. We support various materials with customizable colors, textures, and mechanical properties.
Vacuum Casting Services at Tek4s
Vacuum casting, also known as urethane casting or RTV molding, is a versatile and cost-effective process used to produce small batches of high-quality plastic parts that closely mimic injection-molded components. At Tek4s, our vacuum casting service is engineered for speed, precision, and versatility, making it ideal for prototypes, pre-production runs, and low-volume manufacturing.
1. Process Overview
The vacuum casting process begins with a master model, typically produced using CNC machining or 3D printing. This master is used to create a silicone mold, which captures every surface detail, texture, and dimension with exceptional accuracy. Once the mold is prepared, liquid polyurethane resin is poured into it under vacuum conditions, ensuring complete filling and eliminating air bubbles or voids.
After curing, the casted part is removed, finished, and inspected for dimensional accuracy. Each silicone mold can typically produce 15–25 high-quality replicas before requiring replacement, depending on the part geometry and resin type.
2. Material Versatility
Tek4s offers a wide selection of polyurethane resins that replicate the properties of engineering-grade plastics such as ABS, PP, PC, PA, and rubber-like elastomers. This allows clients to test mechanical, thermal, and visual characteristics before committing to full-scale injection mold tooling.
We also provide clear, tinted, and color-matched materials, along with options for different surface textures — glossy, matte, or soft-touch. For applications requiring enhanced functionality, we can integrate metal inserts, threaded bushings, or overmolding during casting.
3. Accuracy and Surface Finish
One of the main advantages of Tek4s’ vacuum casting is the outstanding surface finish and precision achievable without extensive post-processing. Because the silicone molds are flexible and detailed, they reproduce intricate geometries, undercuts, and textures accurately.
To ensure consistency, we maintain tight dimensional tolerances, typically within ±0.2 mm depending on part size. This makes vacuum-cast parts suitable not only for form and fit testing but also for functional assemblies and end-use applications.
4. Advantages Over Injection Molding
While injection molding is best for high-volume production, vacuum casting excels when:
The quantity required is between 10 to 500 parts
Tooling costs need to be minimized
Design changes are expected during development
Speed to market is a priority
The process eliminates the need for expensive steel or aluminum molds, making it ideal for bridge production — the stage between prototype and full-scale manufacturing.
5. Quality and Finishing Options
At Tek4s, every vacuum-cast part undergoes inspection and finishing to ensure it meets visual and functional standards. Our finishing services include sanding, painting, texture replication, silk-screen printing, and vapor polishing for transparent components.
Additionally, we perform fitment validation and assembly checks for multi-part products, ensuring compatibility and reliable performance in the intended application.
6. Applications
Vacuum casting is widely used in industries such as:
Automotive: Interior trim parts, functional prototypes, and design validation models
Consumer Electronics: Enclosures, housings, and ergonomic prototypes
Medical Devices: Casings, control panels, and user-interface prototypes
Industrial Equipment: Custom housings and covers for limited production
7. Tek4s’ Advantage
What sets Tek4s apart is our engineering-driven approach to vacuum casting. Our experts collaborate with clients from the design stage to ensure optimal mold design, resin selection, and finishing methods. Using 3D CAD modeling, mold flow simulation, and process validation, we guarantee reliable and repeatable results.
With state-of-the-art facilities, Tek4s can deliver finished vacuum-cast parts within days, supporting accelerated product development cycles. Whether you need a single visual prototype or a hundred functional units, our process ensures outstanding precision, performance, and presentation.
Tek4s’ vacuum casting services are not merely about producing parts — they are about enabling innovation and confidence in design validation and pre-production testing.