Vacuum Casting Services in China — Built by a Mold Maker, From Prototype to Production
Get 1–500 high-quality urethane parts from your CAD file in 5–20 days — with a free DFM review for your future injection mold, so today's prototypes don't become tomorrow's tooling rework.
- Free DFM Review for Your Future Injection Mold
- One Partner — Prototype to Production
- All Finishes Included — Paint · Silk Screen · Plating · Polish
- No MOQ · 1 Piece OK · Lead Time 5–20 Days
- NDA First · Transparent Pricing Locked
Free DFM Review
Draft angles · Undercuts · Wall thickness — flagged before tooling
Photo Documentation
Pattern · Mold · Casting · Finish · QC · Ship
What is Vacuum Casting?
Vacuum casting is a low-volume manufacturing process that uses silicone molds and polyurethane resins to produce 1–500 high-quality plastic parts in days, not months. Parts are cast under vacuum to eliminate air bubbles, then heat-cured to develop full mechanical properties — closely matching injection-molded quality at a fraction of the tooling cost.
Vacuum Casting Today. Injection Molding Tomorrow.
KTM is a Dongguan-based factory founded by a mold-design specialist with 20+ years of hands-on experience. We operate both vacuum casting AND injection molding production — so when your design is validated and volume justifies tooling, your project continues into injection molding with the same engineering team that handled your prototypes. One quote, one project lead, end-to-end.
Years of Mold Engineering Experience
Dongguan-based factory · ISO 9001:2015 · Vacuum Casting + Injection Molding
From Mold to Part
Silicone Mold → Urethane Part → Future Injection Mold
End-to-End Manufacturing Flow
CAD File
STEP/STL/PDFMaster Pattern
CNC / SLASilicone Mold
Platinum-cureUrethane Parts
1–500 pcsInjection Molding
500+ pcs1–500
Parts per run
5–20
Day lead time
Free
DFM review
The Vacuum Casting Process — How KTM Delivers Production-Quality Urethane Parts
The vacuum casting workflow turns your CAD file into production-quality urethane parts in six stages:
Master Pattern Creation
CNC machined in-house at KTM, or high-resolution SLA 3D printed when fine surface detail is required.
Silicone Mold Making
The master pattern is submerged in platinum-cure silicone. After cure, the mold is cut open and the master pattern removed.
Vacuum Pouring
Polyurethane resin is poured into the silicone mold under vacuum, eliminating air bubbles and ensuring full cavity filling.
Heat Curing
The mold is heated in an oven to develop the full mechanical properties of the urethane resin.
Demolding & Trimming
Parts are removed; gates, runners, and parting lines are cleaned.
Surface Finishing & QC
Per project requirements, then caliper inspection plus complete photo documentation.
Free DFM Consultation for Your Future Injection Mold
Every vacuum-cast part at KTM is reviewed for future injection-mold compatibility before quoting — free of charge. We flag draft angle issues, undercuts, wall thickness traps, and parting line problems while design changes are still cheap. Built on 20+ years of mold engineering.
Prototype Stage DFM Review
Design changes: cheap & fast
Tooling Rework
8 weeks + cost overrun
The result: catch tooling problems at the prototype stage, not 8 weeks into mold-making.
Tolerances, Build Size & Lead Time
Vacuum casting tolerance is suitable for design validation, fit-check, and low-volume production where injection-mold-grade precision is not required.
| Parameter | Capability |
|---|---|
| Standard Tolerance | ±0.3% (lower limit ±0.3 mm for parts < 100 mm) |
| Minimum Wall Thickness | 0.5 mm (recommended ≥ 1.0 mm for best results) |
| Maximum Build Size | 1,500 × 1,000 × 800 mm |
| Parts per Silicone Mold | 15–25 parts |
| Lead Time | 5–20 business days (size, complexity, surface finishing dependent) |
Polyurethane Materials Matrix — 7 Categories Mimicking Production Plastics
KTM uses polyurethane resins engineered to mimic real production plastics — ABS, PC, PP, rubber, and more. We work primarily with the leading European and Japanese resin brands (Axson, Hei-CAST), and every material category corresponds to a real injection molding plastic. That makes it easier to specify the right material for your future production tooling — no surprises when you transition from vacuum-cast prototype to injection-molded production.
Quick decision guide for engineers in a hurry:
Painted enclosure for consumer electronics or interior trim
→ ABS-Like (Hei-CAST PU8150 / Axson PX-521)
Heat resistance ≥100°C, rigid structural part
→ PC-Like / High-Temp (Hei-CAST PX223HT)
Living hinge, snap-fit, chemical-resistant
→ PP-Like (Axson TPS6000)
Optical-clear lens, light cover, display window
→ Transparent (Axson PUC840) — pair with optical polishing
Soft-touch grip, seal, gasket
→ Rubber-Like (Hei-CAST TC851, Shore A 30–90)
Electrical enclosure requiring UL flame retardancy
→ UL94-V0 (Hei-CAST PU8160)
Not sure which to choose? Send your part drawing and targe
Surface Finishing & Post-Processing — From Cast Part to Ready-to-Show
KTM provides 10+ surface finishing capabilities for vacuum casting parts — from precision printing for control panels to optical polishing for transparent housings.
Optical Polishing: KTM Specialty
Optical polishing for transparent parts is a KTM specialty. We polish clear urethane (Axson PUC840 / PU0511) to mirror-grade finish — used on industrial inspection equipment lens covers, automotive light covers, and display windows. Reaching this level on cast urethane requires multi-step wet sanding from 800 to 4000 grit, followed by polishing compound — a process that takes hand-finishing skill, not machine time.
Inserts Assembly: KTM Specialty
Inserts assembly is more than dropping nuts into holes. KTM embeds brass threaded inserts (M2, M3, M5+) either pre-cast (placed in the silicone mold before pouring) or post-installed (heat-pressed after curing). Pre-cast inserts give better pull-out strength but require precise alignment fixtures — which we build in-house from your CAD assembly drawing.
Pre-Cast Insert
Better pull-out strength · placed before pouring
Post-Installed Insert
Heat-pressed after curing · more flexible
Color matching is done at the resin stage when possible — we mix pigments into the polyurethane before casting, so color goes through the part. For exact RAL or Pantone matches, complex finishes, or multi-color requirements, we apply spray painting over a neutral base. Send a physical color sample or specify a RAL/Pantone code with your RFQ for fastest matching.
Use Cases & Industries — From Prototype Validation to Low-Volume Production
Medical Inspection Equipment
Real Project 1:
A medical inspection equipment manufacturer needed 100+ housing parts with complex internal geometry that prevented standard injection molding (no proper draft angles for ejection at this volume). KTM produced these in ABS-like polyurethane, with M2, M3, and M5 brass inserts pre-embedded for instrument-panel assembly, and silk-screen-printed control labels. 100+ sets delivered.
Why customers choose us: Tight insert tolerance, durable inserts assembly capability, complete photo documentation for traceability needs.
Industrial Equipment
Real Project 2:
An industrial customer needed transparent housings with optical clarity for an inspection-equipment lens cover. KTM cast the parts in PC-like polyurethane and finished them with mirror-grade optical polishing — a KTM specialty for clear urethane parts. 200+ sets delivered.
Why customers choose us: Optical-grade transparent urethane, KTM's mirror polishing capability, durable for industrial environments.
Automotive (Low-Volume / Pre-Production)
Real Project 3:
An automotive Tier-2 supplier needed 50 sets of an interior housing where injection mold tooling was not economically justified at this volume. KTM produced the parts in ABS-like polyurethane through vacuum casting, delivered with full assembly verification photos. 50+ sets delivered. Why customers choose us: Mold-maker's DFM advantage — when volume grows, KTM transitions you directly into injection molding production.
Why customers choose us: Mold-maker's DFM advantage — when volume grows, KTM transitions you directly into injection molding production.
Decision Framework — Vacuum Casting vs Injection Molding
When does vacuum casting make sense — and when should you transition to injection molding?
1–100 parts
Vacuum Casting
100–500 parts
Vacuum Casting ×molds
500+ parts
→ Injection Molding
| Your Volume | Recommended Path | Why |
|---|---|---|
| 1–100 parts | Vacuum Casting | Injection mold tooling cost not economically justified |
| 100–500 parts | Vacuum Casting (multiple molds in parallel) | Still more economical than tooling investment |
| 500+ parts (single design) | Transition to Injection Molding | Tooling cost amortized; faster cycle time per part |
| Design validation before tooling | Vacuum Casting → Injection Molding | De-risk design before committing to mold investment |
The "DFM Translation Tax" Warning
This is where most projects lose time. The supplier handoff between prototyping and tooling typically costs a "DFM translation tax" plus 4–8 weeks of timeline. KTM continues directly into injection molding production with the same engineering team — your CAD data, DFM notes, and quality history transfer in one move.
Quality Control & Photo Documentation — Validated, Visualized, Verified
The Right Inspection for Vacuum Casting
Vacuum casting is designed for low-volume validation and pre-production builds — not for injection-mold-grade precision. So we don't oversell what's not needed. KTM inspects every vacuum-cast part with calipers, micrometers, plug gauges, and visual inspection in our in-house metrology lab — the right tools for the right tolerance class. CMM dimensional reports remain available on request for parts requiring critical-dimension verification.
In-House Inspection Equipment
- CMM (on request, for critical-dimension verification)
- Optical projector & 2D vision measurement
- Calipers, micrometers, height gauges
- Pin gauges, plug gauges, go/no-go gauges
- Material hardness testers
Every Part. Every Shipment.
Caliper + Photo Documentation
Photo Documentation Package
Every vacuum casting shipment includes a complete photo documentation package — process images covering each stage, plus assembly verification photos for parts with embedded inserts.
You see what we see, at every stage.
Master Pattern
CNC/SLA finished
Silicone Mold
After cure & cut
Casting
Vacuum pour complete
Post-Processing
Surface finishing
Final QC
Caliper check
Assembly Verification
Insert confirmation
How to Start Your Vacuum Casting Project — From RFQ to Delivery in 5 Steps
Single-source accountability across every step. NDA signed before any drawing review. Fast English communication for daily updates, and engineering escalation for complex technical decisions — so you always have someone who understands manufacturing physics behind every email.
Submit RFQ
Send drawings, STEP/STL/PDF files, material & quantity. NDA signed first if requested.
Design Review
Our engineering team reviews your part for castability AND flags any features that will cause problems in your future injection mold. Free with every quote.
Quote Locked
Transparent pricing covering master pattern, silicone molds, polyurethane, surface finishing, QC, packaging, export documentation.
Production with Progress Reports
Photo documentation at every key milestone.
Delivery
Delivery with Photo Documentation Package
| Step | Action | Timeline |
|---|---|---|
| ① | NDASubmit RFQ — Send drawings, STEP/STL/PDF files, material & quantity. NDA signed first if requested. | Day 0 |
| ② | Free DFM ReviewDesign Review — Our engineering team reviews your part for castability AND flags any features that will cause problems in your future injection mold. Free with every quote. | 1–2 business days |
| ③ | Quote Locked — Transparent pricing covering master pattern, silicone molds, polyurethane, surface finishing, QC, packaging, export documentation. | 1-2 business day |
| ④ | Photo DocumentationProduction with Progress Reports — Photo documentation at every key milestone. | 5–20 business days |
| ⑤ | Delivery with Photo Documentation Package | Per agreed Incoterm |
A Mold Maker's Approach to Vacuum Casting, from Prototype to Production
You're not looking for just a vacuum casting supplier. You're looking for a partner who can take your design from validation through to mass production — without losing context, without supplier handoffs, without paying a "DFM correction tax" later when your injection mold turns out to need 6-8 weeks of rework. That's what KTM was built for.
One Roof, Two Stages
Vacuum Casting + Injection Molding
Prototype to Production — One Partner
RFQ + NDA
Day 0
DFM Review
Free
Vacuum Casting
1–500 pcs
Design Validated
Prototype proven
Injection Molding
500+ pcs
Mass Production
Same team
Mold-Maker's Eye, Prototype Speed
Built by a mold-design specialist with 20+ years of hands-on factory experience, every vacuum-cast part is reviewed for future injection-mold compatibility — free of charge. We tell you which features won't survive a real production tool before you tool up. Save 30–50% future mold modification costs · cut 4–8 weeks off your future mass production timeline. This is what "Built by a Mold Maker" means in practice — not a tagline, but a free engineering review on every project.
One Partner, Two Stages — Prototype to Production
KTM operates both vacuum casting and injection molding production. When your design is validated and volume justifies tooling, your project continues directly into injection molding — same engineering team, same CAD data, same QC standards. Some KTM customer relationships are measured in 10–15 years of repeat partnership, built by keeping the entire prototype-to-production path under one roof of accountability.
Engineering-Led, Not Sales-Led.
Daily project communication runs through experienced English-fluent project managers (5–10 years experience) for fast updates. But complex technical decisions escalate directly to our mold-engineering team — and to the founder, a mold-design specialist with 20+ years of factory experience. You always have someone who understands manufacturing physics behind every email. No marketing layer between you and the people who actually engineer your project.
Finishing Capability + Honest Economics
And when finishing matters — painting, silk screen, electroplating, optical polishing for clear parts — KTM handles it all. One partner, every finish. Honest economics: we'll tell you when to stay with vacuum casting and when it's time to scale into injection molding tooling — even if that means a smaller order today and a bigger one tomorrow.
Pricing Framework — What Drives Your Vacuum Casting Cost
Transparent pricing — no hidden charges. Five variables determine your quote, and your price stays locked once the order is confirmed.
| Item | Driver | What It Means |
|---|---|---|
| 1 |
Master Pattern Cost
|
CNC machining or SLA 3D printing — varies with size and complexity |
| 2 |
Silicone Mold Count
|
1 mold = 15–25 parts. 100 parts ≈ 4–5 molds. Volume drives mold count. |
| 3 |
Polyurethane Material
|
Standard ABS-like is base. Transparent / High-Temp / UL-V0 add cost. |
| 4 |
Quantity & Lead Time
|
Higher quantity reduces unit cost. Rush orders incur a premium. |
| 5 |
Surface Finishing
|
Painting / silk screen / electroplating / optical polishing — priced per process |
Quote Includes Everything
Price Locked Once Order is Confirmed
As long as drawings, 3D files, and specifications remain unchanged. Any change order is fully quoted in writing before we proceed.
Our 4 Commitments — How KTM Removes Your Risk
Confidentiality Assured — NDA First
NDA FirstYour design stays yours. We sign your NDA before any drawings or 3D files are reviewed. Files are stored with encrypted, need-to-know access — not shared with anyone outside your project team. Upon project completion, you can request file deletion in writing.
Transparent Pricing — Quote Locked
Quote LockedYour quote covers everything from master pattern through export documentation. We don't move the goalposts mid-project — as long as your specifications stay the same, your price stays the same. Change orders are quoted in writing first, never billed retroactively.
Progress Reports — You Always Know Where We Are
Progress ReportsPhoto documentation at every key milestone. Weekly updates for longer projects. Engineering escalation when complex issues arise — no black-box production.
Quality Resolution — We Investigate, We Fix It
48-Hour ResponseIf a part doesn't meet spec, send photos and measurement data. Our engineering team responds within 48 hours with a clear plan — repair or remake based on root cause analysis. Every quality concern is tracked from report to closure with documented decision rationale, not informal email back-and-forth.
Frequently Asked Questions
Lead time is 5–20 business days. Simple parts without finishing ship in 5–8 days; complex parts with multi-step finishing ship in 12–20 days. Rush options available on request.
Yes. KTM operates both vacuum casting and injection molding production. Once your design is validated, your project continues into injection molding tooling with the same engineering team that handled your prototypes.
Every shipment includes our Photo Documentation Package — process images at every stage, caliper measurement records, and assembly verification photos. CMM reports available on request for critical-dimension parts.
Yes. NDA signed before any drawing review. Files stored with encrypted, need-to-know access, not shared with anyone outside your project team. File deletion available on written request after project completion.
1 silicone mold produces 15–25 parts (closer to 15 for complex undercuts, 25 for simple geometries). 100 parts ≈ 4–5 molds. Beyond 500 parts, injection molding becomes more economical.
KTM offers 7 polyurethane categories — ABS-like, PC-like, PP-like, rubber-like, transparent, high-temp, and UL94-V0 — primarily from Axson and Hei-CAST. Each maps to a real injection molding plastic for easier production transition.
Vacuum casting wins for 1–500 parts, design validation, or geometries that can't eject from a steel mold. Injection molding wins at 500+ parts where tooling cost amortizes across the run.
Minimum 0.5 mm. Recommended 1.0 mm or thicker for best results. Wall thickness consistency matters — sudden transitions cause warpage. Our DFM review flags problem zones before tooling.
10+ finishes — painting (RAL/Pantone), silk screen, pad printing, electroplating, UV coating, laser engraving, optical polishing for transparent parts, sandblasting, and M2/M3/M5 brass inserts assembly.
Five variables drive cost: master pattern, silicone mold count (1 mold = 15–25 parts), polyurethane material grade, quantity and lead time, and surface finishing scope. Quote includes everything — locked once order is confirmed if specifications remain unchanged.
Ready to Start Your Vacuum Casting Project?
Submit your drawings, STEP/STL files, or part specs — KTM signs NDA before review. Our engineering team responds within 24 hours with a transparent, locked quote, including a free DFM consultation for your future injection mold.
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