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Vacuum casting

Vacuum casting is a means of casting small metal parts or jewelry that have fine detail or for casting various plastic materials. A porous or vented mold is used and is placed on a table or container where vacuum is applied. The liquid to be cast will be driven into the mold by atmospheric pressure, while the vacuum will also remove trapped air that would otherwise impede the free flow of the liquid casting material. Vacuum casting is applied as an alternative to centrifugal casting of metals which is used in similar situation Now vacuum casting is being used for Rapid Prototyping to prepare SILICON MOULD This Silicon mould is used to produce resin prototypes which helps in studying design features and try various design iterations in short period of time

Steps in Vacuum Casting


Preparation of Silicon Mold using Master Model Preparation of Mold frame with master model
 Positioning master model according to partition line  Gating

Preparation of Silicon Pouring of silicon in to the mold frame Opening the silicon mold along the partition line Remove the master model Preparation of Prototype using Silicon Mold Fix the silicon mold along the partition line and pin it air tight Place the silicon mold in Vacuum chamber Fill the resin and required gas (helium,argon as required) Give the required inputs in the control panel of the chamber After the process is over open the model and remove the prototype

Making the Silicone Mold


Preparation of Master Model Positioning of Parting Line

GATING

Fixing the master model in the molding frame

MIXING OF THE SILICONE PRIMARY DEGASSING OF THE SILICONE

SECONDARY DEGASSING OF THE SILICONE CURING OF THE SILICONE

OPENING SILICONE MOLD

SEPERATION OF MASTER PIECE AND SILICONE MOLD

PREPARING SILICONE MOLD

Production of Parts
CALCULATION OF REQIURED QUANTITY OF RESIN MIXING OF COMPONENTS OF RESIN POURING OF RESIN INTO THE MOLD CURING OF RESIN SEPERATION OF MOLD AND PART

MIXING AND POURING OF RESIN

Machine Specifications
Maximal Mold Size : 450 x 470 x 400 mm Maximal Casting Weight : 1000 g Chamber Interior size : 450 x 470 x 700 mm

SAMPLES OF REPLICATED PARTS

SUMMARY OF THE ENTIRE PROCESS

RESINS
MK-Easy MK-Clear MK-Rubber MK-Carbon

CASTING RESINS TECHNICAL DATA


Type of Resin Similar to MK-Easy PE/PP MK-Clear PMMA/PC MK-Rubber PVC, Soft MK-Carbon ABS, Reinforced Black 82 s 2 53 s 2 81 s 1.6

Color Final Hardness Shore D/1 Tensile Strength N/Sq.mm Flexural Strength N/Sq.mm Flexural Modulus N/Sq.mm Elongation % Shrinkage % Density g/cubic cm Viscosity at 25 deg.c. m PA.s

WhiteYellow 85 s 2 55 s 2 65 s 2

Transpare nt 80 s 2 47 s 2 67 s 2

Black 75 s 1 7.5 -

1.5 s 100

1.5 s 100

5.9 s 500

10 s 2 0.2 1.10 75 s 10

20 s 2 0.2 1.06 1.0 s 200

300 0.3 1.10 700 s 100

1.1 s 0.04 0.25 1.4 1.60

TECHNICAL DATA OF MK- SILICONE RUBBER


Color Final Hardness Shore A Translucent

40

Tensile Strength N/sq.mm Elongation %

5.7

300

Tear Strength N/mm

21

Viscosity mPA.s

42

Density at 25 deg.c g/Sq.cm Shrinkage %

1.12

< 0.1