Why choose vacuum casting for 20 automotive prototypes?
At an early design stage, a customer may need a small set of similar parts for engineering review without paying for an injection mould. Vacuum casting reproduces a prepared master pattern in a silicone mould, allowing a short run of plastic-like parts. It gives the team more samples to assemble and compare while the design is still open to changes.
The choice depends on the intended tests. Here, the customer considered direct 3D-printed parts insufficiently strong for its planned evaluation, while steel tooling was too costly for 20 pieces. The PC-like casting resin was selected for the prototype requirement. It must not be assumed to have the same properties as injection-moulded polycarbonate. If impact, temperature, flammability, VOC or other automotive interior performance tests are planned, the resin grade and test requirements need to be agreed before production.
How the black interior parts were made
The starting point was the customer's 3D model and drawing. Particular attention was needed around the perimeter lip, rib intersections and mounting features, where fit and handling can be sensitive to dimensional change. A master pattern was prepared for the silicone mould, then PC-like polyurethane resin was cast to produce the 20 parts.
Black colour was mixed into the casting resin, eliminating a separate painting step. The final colour and surface texture can be confirmed against a reference if they are cosmetic acceptance criteria. The castings were then demoulded, trimmed and checked against the agreed drawing.
For this type of vacuum-cast part, ±0.1 mm is a general dimensional expectation, not a promise for every feature. Part size, wall thickness, cure shrinkage and geometry can affect the result. Engineers should mark critical mounting dimensions and mating surfaces on the drawing so they can be reviewed and inspected specifically.
The stated project time for silicone mould making and sample production was approximately 7–10 days. A firm delivery date for another design follows the CAD review and confirmation of material, finish and inspection requirements.
What the development team can check
With 20 matching prototype parts, the customer can run several trial assemblies, compare the fit of the perimeter and mounting features, and collect feedback from different reviewers. This is useful before deciding whether to adjust the geometry or proceed to injection mould tooling. The prototypes are intended for the agreed development checks; their suitability for durability or regulated automotive tests depends on the actual casting resin and test plan.
Request a quote for low-volume plastic prototypes
YS Rapid provides vacuum casting services for automotive interior prototypes and other low-volume plastic components. Send us the 3D CAD file, drawing, target quantity, colour reference, critical fit dimensions and intended tests. We can review whether silicone mould casting suits the design, identify dimensions that need special attention and quote the tooling and casting work.
EN
jp 
ko 
fr 
de 
es 
it 
pt 
tr 
ar 
iw 
