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Clear Resin Vacuum Casting

Clear Resin Vacuum Casting

Clear resin vacuum casting produces optically transparent prototypes and short-run parts using premium polyurethane resins poured under vacuum into silicone molds. The process supports lenses, light pipes, fluid-flow models, transparent housings, and clear short-run end-use parts — without the tooling cost or lead time of injection molding.
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Description

Material Performance & Consistency

 

Clear resin vacuum casting produces optically transparent prototypes and short-run parts using premium polyurethane resins poured under vacuum into silicone molds. The process supports lenses, light pipes, fluid-flow models, transparent housings, and clear short-run end-use parts - without the tooling cost or lead time of injection molding.

Core advantages:

  • High optical clarity: premium clear polyurethane resins typically achieve light transmittance of 85–92% on polished cast parts.
  • Tight tolerances: standard tolerance of ±0.2 mm per 100 mm, supporting accurate fit in complex assemblies.
  • Rapid turnaround: first samples typically delivered in 7–10 working days from approved master pattern.
  • Cost-effective for low volumes: well-suited to 1–500 piece programs, avoiding the high upfront cost of clear-resin injection tooling.
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Geometric Capabilities

 

The flexibility of silicone molds lets vacuum casting achieve features that are difficult or expensive for CNC machining or injection molding:

Integrated inserts:

metal threaded inserts and other components can be over-molded directly into the clear part.

Undercuts & deep cavities:

easily handled - no sliding actions or lifters required, since silicone tooling flexes during demolding.

Thin walls:

thin sections down to 0.8 mm achievable while maintaining structural integrity (geometry-dependent).

Optical surfaces:

streamlined curves and lens surfaces produced with uniform refractive quality, supported by polished masters and selective post-polishing.

 

Technical Specifications

 

Parameter

Specification

Maximum part size

Up to 800 × 600 × 400 mm (larger on request, subject to mold-frame size)

Standard tolerance

±0.2 mm or ±0.2% per 100 mm (whichever larger)

Minimum wall thickness

0.8 mm

Light transmittance

85–92% (polished, resin- and finish-dependent)

Refractive index

~1.49–1.51 (typical for clear urethane)

HDT

70–90 °C (resin-dependent, @1.82 MPa)

Hardness range

Shore D70–90 standard; soft transparent grades (Shore A70–A90) available

Color options

Optically clear, tinted, or translucent (custom color matching)

Surface finishing

Hand polishing, vapor polishing, UV-resistant coating, silk-screening

Light transmittance values are typical for premium clear urethane resins after polishing; specific values depend on the resin grade and finishing process. Detailed resin data sheets are provided per project.

 

Material Options

 

We support a range of clear polyurethane casting resins matched to functional requirements:

Standard clear PU:

 balances transparency and rigidity - ideal for most consumer-electronics housings and visual prototypes.

 

Heat-resistant clear PU:

 higher heat-deflection temperature for automotive lamp covers and components seeing elevated service temperatures.

 

ABS-equivalent clear resin:

 improved toughness and impact resistance for functional-assembly testing.

 

Flexible clear (TPU-equivalent):

adjustable Shore hardness for clear gaskets, seals, or flexible prototypes.

 

 

Applications

 

1
Medical devices:
flow-visualization models, fluid manifolds, transparent device housings.
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Automotive:
headlamp and tail-lamp lens prototypes, light guides, transparent interior dashboard components.
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Consumer electronics:
wearable device windows, smartphone case prototypes, LED light diffusers.
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Industrial design:
sight glasses, industrial windows, high-end display models.

 

FAQ

 

Q1: What is clear resin vacuum casting?

A manufacturing process in which a master pattern (typically CNC-machined or SLA-printed) is used to make a silicone (RTV) mold. Liquid clear polyurethane resin is then poured into the mold under vacuum, producing transparent parts that closely resemble injection-molded acrylic or polycarbonate.

Q2: How does vacuum casting achieve optical clarity?

Processing the resin under vacuum removes air bubbles before and during casting. After demolding, parts undergo multi-stage hand polishing and are typically finished with a clear UV-resistant coating to maximize transparency and resist long-term yellowing.

Q3: What is the minimum order quantity (MOQ)?

There is no MOQ - single prototypes through small batches of 100+ units are supported.

Q4: How does clear resin vacuum casting compare with injection molding?

For aesthetics, a polished vacuum-cast part is visually very close to an injection-molded clear part. Mechanical and long-term properties are typically 80–90% of the equivalent production plastic, while lead time and tooling cost are substantially lower for low volumes. For long-term outdoor exposure, very high temperatures, or strict optical-grade requirements, injection-molded PMMA or PC is generally preferred for production volumes.

Q5: Can you add tints or coatings to clear cast parts?

Yes. Resins can be tinted to match Pantone references for smoke or coloured-glass effects. UV-resistant clear coatings are also available to slow long-term yellowing.

Q6: How many clear cast parts can be produced from one mold?

Each silicone mold typically supports 20–25 clear castings before mold wear and surface aging affect optical quality. A rigid master pattern can be used to make multiple silicone molds for higher total quantities.

Q7: What file formats are accepted?

STEP (.stp / .step), IGES (.igs / .iges), and STL files are accepted. 2D drawings with tolerance callouts are recommended for parts with critical fits.

Q8: What are typical lead times?

Silicone mold-making typically takes 1–2 working days, with casting and finishing taking another 5–8 working days. Most projects are delivered within 7–10 working days.

Q9: Is vacuum-cast clear resin food-safe or biocompatible?

Specific resin grades meet certain biocompatibility or food-contact standards. Please specify regulatory requirements at quotation so the appropriate grade can be selected and documented.

 

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