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HIGH On 3D

Vacuum Casting

Injection-moulding quality parts — without the tooling cost or the wait

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Vacuum Casting

Tool-Free Pre-Series Molding: The Vacuum Casting Workflow

Vacuum Casting (Polyurethane Molding) is the premier low-volume manufacturing bridge between initial 3D printed prototypes and full-scale injection molding.

At HIGH On 3D, we utilize high-precision master models and reinforced silicone tooling inside high-vacuum chambers to produce bubble-free plastic parts. This process delivers exact color-matching, spark-eroded surface textures, living hinges, and elastomeric flexibility—all with zero capital expenditure on hard steel tooling.

As a leading vacuum casting service provider operating alongside our 3D printing setup, we offer short-run polyurethane molding in production-grade materials mimicking ABS, PC, Polypropylene, and high-durability Silicone (10A to 90A Shore hardness). Designed to bridge the gap to mass production, our team delivers export-grade pre-series batches, overmolded enclosures, and clear optical housings to automotive OEMs and hardware companies globally within 7 to 10 days.

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What our clients cast

From investor-demo housings to functional rubber seals, vacuum casting suits almost any part where you need a realistic batch fast.

Large-Format Vacuum Chamber (1450 × 750 × 750 mm)

  • Capability: Industry-leading chamber capacity for casting massive single-piece housings or batch-casting multiple components simultaneously.
  • Recommended Applications: Vehicle dashboards, bumper grilles, large medical diagnostic enclosures, and industrial equipment covers.

Reinforced Silicone Tooling (Up to 40+ Shots)

Advanced Polyurethane Resin Degassing

What our clients cast

High-Performance Polyurethane (PU) Materials

A selection of our standard resin grades matching production polymers.

Resin GradeEquivalent MaterialPrimary CharacteristicsKey Applications
Synthene PR-700ABS (Black)High impact strength, good rigidityAutomotive housings, general-purpose covers
Synthene PR-777PP (White)High flexibility, excellent living-hinge & snap-fit behaviorSnap-fit enclosures, covers, functional clips
Hie Cast - 8400TPU / EPDM RubberFlexible elastomeric properties, high tear resistanceSeals, gaskets, protective boots, dampening pads
Synthene PRC 1810PC (Transparent)Optical clarity, UV stability, high polishLighting lenses, clear covers, optical components
Hie Cast - 8150Flame Retardant ABSUL94 V-0 flame rating, structural stabilityBattery cell holders, medical devices, electronics
SikaBiresin PX223 HTHigh-Temp ABSThermal resistance under continuous heat loadEngine bay parts, intake manifolds, hot fluid housings
Synthene PR752High-Temp PEEK / ABSExtreme thermal & chemical resistanceFluid reservoirs, oil tanks, industrial valve components

Key Benefits

Delivering performance, precision, and production efficiency with every build.

Injection-Molded Finish

Achieve professional molded surface textures, high-gloss polishes, or custom Pantone color matching straight out of the tool.

01

Fast Tooling Lead Times

Produce functional silicone molds in just 3 to 5 days, compared to 6 to 12 weeks for steel injection dies.

02

Multi-Material Flexibility

Cast rigid housings, flexible rubber gaskets, and clear lenses—or combine them using two-shot overmolding.

03

Risk Reduction for Mass Production

Validate part fit, form, and market demand before committing lakhs to high-volume injection molds.

04

How to Get Started

01

Submit CAD Model or Sample Part

Send .STEP / .IGES CAD file or physical master part.
Upload your 3D CAD design or send a physical prototype for mold design and draft angle verification.
02

Choose Material & Finish Specifications

Select PU resin grade, color tint, and surface texture.
Specify your target polymer equivalent (ABS, PP, Rubber, PC), Pantone color, and surface finish (textured, gloss, matte).
03

Approve First Article & Receive Batch

Silicone mold creation and vacuum resin casting.
Inspect the First Article Inspection (FAI) sample before we cast your complete low-volume production batch in 1 to 2 weeks.

Have a design ready for a pilot batch?

Upload your CAD or STL file and our engineers will recommend the right resin, finish and batch size — with a transparent, GST-compliant quote for pan-India delivery.

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Industries we serve across India

Product teams across India's core manufacturing sectors rely on our vacuum casting to validate designs and produce pilot batches — from automotive and medical to electronics, consumer goods and defence.

Automotive

Automotive

Interior trims, ducts, brackets and functional parts for OEMs and Tier-1 suppliers validating form, fit and function.

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Aerospace & Aviation

Aerospace & Aviation

Lightweight, high-strength prototypes and test-fit components for next-generation flight systems.

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Medical Devices

Medical Devices

Ergonomic enclosures and handles for usability studies, demos and pre-certification samples.

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Robotics & Automation

Robotics & Automation

Custom grippers, sensor arrays and lightweight robotic components for autonomous systems.

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Defense & Military

Defense & Military

Low-volume, high-detail components and fit-check parts for regulated, small-batch programmes.

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UAV & Drones

UAV & Drones

High-performance, lightweight airframes and aerodynamic prototypes for advanced drone applications.

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Frequently Asked Questions

The questions Indian buyers ask most before starting a vacuum casting project. Still unsure? Talk to our engineers.

How many parts can I get from one silicone mould?
Typically 20-25 parts before the silicone mould wears and needs replacing. For larger batches we simply build additional moulds, and the per-part cost keeps falling with quantity.
Is vacuum casting cheaper than injection moulding in India?
For low volumes — up to a few hundred parts — yes, significantly. Injection moulding requires an expensive steel tool (often lakhs of rupees) that only pays off at thousands of units. Vacuum casting skips hard tooling, so you get production-quality parts for a fraction of the upfront cost.
What materials and hardness options are available?
A wide range of polyurethane resins that mimic ABS, PP, PC and clear PMMA, plus rubber-like grades from Shore 40A to 90A, and heat-resistant, glass-filled and flame-retardant (UL94 V-0 class) options. We help you match the resin to your mechanical, thermal and aesthetic needs.
What is the typical lead time for vacuum casting?
About 7-12 working days from approved CAD to the master, silicone mould and first cast parts, depending on size, quantity and finish. Rush timelines can often be accommodated — just ask.
Do you provide GST-compliant invoicing and pan-India delivery?
Yes. We are a Pune-based, ISO 9001:2015 certified company offering fully GST-compliant invoicing and reliable, insured delivery across India — Mumbai, Bengaluru, Delhi-NCR, Chennai, Hyderabad, Ahmedabad and everywhere in between.
Can you cast transparent, coloured or overmoulded parts?
Absolutely. We offer optically clear PU, Pantone/RAL cast-in colours, painted and soft-touch finishes, threaded metal inserts and hard/soft overmoulding — so your parts look and function like the final product.

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Have a part? Get a quote in 24 hours.

Upload your CAD and our engineers will recommend the right process, material and finish — with pricing and lead time. Trusted by 150+ clients.

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