Vacuum Casting Explained: Cost-Effective Small-Batch Prototype Production

Vacuum casting is a manufacturing process in which a silicone mold is created using a master model produced by 3D printing or CNC machining. Liquid plastic resin is then poured into the mold and cured to form the final parts.
This method enables the production of small batches of dozens of parts or prototypes within a short lead time.

Compared to direct 3D printing, vacuum casting is often more cost-effective and faster for producing when manufacturing above a certain volume, making it a popular choice during the prototyping stage.

Advantages of Vacuum Casting

Uniform material properties thanks to the curing process of liquid resins
Wide range of materials available, such as ABS, PC, and TPU-like resins
Significant savings in cost and lead time compared to metal injection molds
Multi-material and overmolding capability allows integrated parts to be produced in one process

Thanks to these advantages, vacuum casting has become a key manufacturing method that enhances product development competitiveness across various industries.

OG 이미지 — With one silicone mold, we created parts in different materials using vacuum casting, enabling material property testing.

Things to Consider

When planning prototype production, you may wonder:

Should the master model be made by 3D printing or CNC machining?
From what quantity does vacuum casting become more economical than 3D printing?

In such cases, Creallo’s experts can provide tailored consultation. Our dedicated engineers analyze product characteristics, production quantity, and cost requirements to recommend the most suitable manufacturing process.

Case Study: TPU/PU-like Material Prototypes

TPU/PU-like resins are highly suitable for vacuum casting.
They offer flexibility and durability, making them an excellent alternative to rubber or silicone.

Below is a sample produced with Creallo’s vacuum casting process using TPU material.
Such prototypes are often used to verify performance and quality before mass production.

진공주형 vacuum casting.jpg — *Vacuum casting sample with TPU-like material*

Beyond TPU/PU-like resins, many other materials are also available for vacuum casting.

[Check here for more available materials.]

Creallo’s Vacuum Casting Service

Vacuum casting provides a fast and cost-effective solution for producing small batches of consistent, high-quality prototypes, as well as for pre-mass-production validation.
It is an ideal process for developers and engineers who need to balance speed, cost, and quality in product development.

Creallo leverages its extensive experience, state-of-the-art equipment, and a verified production network to deliver superior vacuum casting services.