How much does vacuum casting cost?

Vacuum casting is a versatile manufacturing process often chosen for its ability to produce precise, high-quality prototypes and low-volume production components. Its flexibility in material options and efficiency makes it a preferred choice across industries. However, understanding the associated costs is crucial for maximizing its benefits. 

Materials Suitable for Vacuum Casting

Vacuum casting uses a wide range of resins and plastics to create parts with diverse mechanical, thermal, and aesthetic properties. Common materials include:

Polyurethane Resins (PU)

Mimics various materials such as rubber, plastic, or even metal.

Cost: $5 to $15 per kilogram, depending on specific properties.

ABS (Acrylonitrile Butadiene Styrene)

Known for its excellent toughness and impact resistance, ideal for functional parts.

Cost: $8 to $15 per kilogram.

PP (Polypropylene)

Lightweight and durable, often used for automotive and consumer product components.

Cost: $6 to $12 per kilogram.

Epoxy Resins

High strength and superior adhesion, suitable for parts requiring durability.

Cost: $10 to $30 per kilogram.

Acrylic Resins

Transparent and aesthetic materials are used for optical parts.

Cost: $10 to $20 per kilogram.

Silicone Rubbers

Used primarily for mold creation, ensuring precision and durability.

Cost: $25 to $40 per kilogram for high-grade silicone.

Kaierwo's Material Offerings

Kaierwo is a trusted provider of vacuum casting solutions for a wide range of applications, often using materials commonly used in the industry, such as polyurethane resins, ABS and PP.

Custom Material Options

One of the advantages of working with Kaierwo is the ability to order materials tailored to specific needs. Beyond its standard offerings, Kaierwo can source and utilize specialty resins or polymers that meet unique customer demands, whether for enhanced heat resistance, flexibility, or aesthetic finishes. This flexibility allows customers to achieve tailored results for prototypes or small production runs.

Cost Breakdown of Vacuum Casting

The cost of vacuum casting is influenced by multiple factors:

1. Material Costs

Materials constitute 40–60% of the total expense. For instance, producing a prototype with ABS using a silicone mold typically costs between $300 and $800 for a batch of 10 units.

2. Mold Production Costs

Creating silicone molds is essential but involves significant upfront costs. A mold costs between $100 and $500 and can be reused for 20–30 casts.

3. Production Volume

Low-volume production (10–50 units) typically reduces per-unit costs to $20–$50, especially for straightforward designs.

After long-term manufacturing experience and research within the industry, we can summarize the efficiency of vacuum casting as follows:

Material Utilization: Produces only 5–10% waste, compared to 20–30% for CNC machining.

Cycle Times: Parts can be completed in 2–4 days, significantly faster than traditional tooling.

Cost Comparison: For small batches, vacuum casting offers 30–60% savings compared to injection molding.

Optimizing Costs in Vacuum Casting

To maximize efficiency and minimize costs:

Material Selection: Use materials that match the exact requirements of the application, avoiding over-specification.

Design Optimization: Simplify designs to reduce mold complexity.

Batch Planning: Larger orders help distribute mold costs and lower per-unit pricing.

Conclusion

Vacuum casting offers a cost-effective, low-cost solution for prototyping and low-volume production, but the hidden costs of time, effort, and the need for secondary verification that the finished product is exactly what you need are also options you need to look at. So make sure you choose to work with an experienced manufacturer that can save you these hidden costs and make your design perfect!