Prototype Module
2009
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Prototype Module
Vacuum Casting – How it Works
Vacuum casting is a form of RTV moulding used widely in creating correct silicone tools for achieving parts casting with very thin walls and fine details. They are exact replicas of the patterns, the dimensions are accurate and have no blemishes; the entire textures and profiles are reproduced faithfully.
Prototyping is an alternative methodology employed in producing prototype castings that copy injection moulded parts like PP, ABS, PA, PMMA as well as various grades of rubber. When the appropriate heated cup module is used, production of accurate, complex wax models for investment is achieved.
Vacuum Casting Process
The process involves these major steps;
• Production of a pattern with any RP process available is the initial step; the RP processes include FDM, SLS and SLA.
• The pattern produced in step one is fitted with a casting gate; subsequently, it is set up on the parting line, followed by its suspension in a mould casting frame.
• As soon as the two part silicone rubber undergoes de-aeration process and is mixed, the next thing is to pour it into the mould casting frame within the pattern
• A heating chamber is used to enclose the mould in order to cure it right there. Subsequently, the pattern is taken away from the silicone mould; this is achieved by cutting along the parting line.
• Next, measuring of the urethane resin is accomplished; for coloured components, dye is added, then the placement of the casting funnels is achieved. Afterwards, the mould is closed and then sealed.
• The mixing and pouring of the resin into the vacuum chamber is accomplished by the computer-controlled equipment. Since this is accomplished in a vacuum, no voids or air-pockets are left when filling the mould – it is filled completely.
• When the resin is casted, the urethane part is cured by moving the mould into the heating chamber for about 4 hours or slightly less.
• The casting is taken out from the silicone mould after the hardening process. Then, in order to mimic the pattern perfectly, the gate and
risers are removed or cut off. On demand, painting or plating of the component accompanies.
The above process is a brief of how cnc prototyping or vacuum casting is accomplished; a good place on the web to find out detailed information on rapid prototyping china is prototypingchina.com.
Benefits of Vacuum Casting
This process results in a number of advantages or benefits such as; providing great dimensional accuracy as well as surface finish when compared to sand castings, there is no issue of gas hole defects, the process also avoids the use of binders and reduces the issue of sand waste. Since the contact between the pattern and the sand is eliminated with this process, pattern life is more protracted. In comparison with other casting techniques, prototyping is quite cost competitive; again, the process can be applied to complex geometrics, and better consistency and productivity can be realized by using automated technique. Vacuum casting is a good match for different range of casting sizes.
About the Author
Roger Linden is the author of this article on Vacuum Casting. Find more information about Prototyping here.
AVR CRUMB128 prototyping module
