Silicone Mould Rapid Prototyping
Silicone mould casting bridges the gap between 3D printing (1-10 parts) and injection moulding (10,000+ parts). Using a 3D-printed master, we create RTV silicone moulds and cast polyurethane resins that closely simulate ABS, PC, PP, and rubber—delivering 20-200 production-representative parts in 5-10 working days.
Process
1. Master model: 3D printed in SLA resin with surface finishing to desired texture. 2. Silicone mould: RTV silicone poured around the master, cured 24 hours, then cut open. 3. Casting: Two-part polyurethane resin vacuum-cast into the mould. 4. Post-processing: deflashing, painting, assembly as needed.
Each silicone mould produces 15-25 parts before replacement. For larger quantities, we produce multiple moulds from the same master.
Material Simulation
Polyurethane casting resins simulate the mechanical properties of common thermoplastics: ABS-like (Heicast 8150, Shore D 78), PC-like (transparent, Heicast 8263), PP-like (flexible, Heicast 8740), and rubber-like (Shore A 40-90). Colour matching to any RAL or Pantone reference.
When to Use Silicone Mould Prototyping
Market testing with production-representative parts, investor presentations, functional testing before committing to steel tooling, bridge production while moulds are being built, and replacement parts for discontinued products in small quantities.
Quality
Dimensional accuracy: ±0.2mm for features up to 100mm. Surface finish replicates the master model. Assembly fit validated against mating parts. Material properties verified through tensile and impact testing on sample coupons.
Frequently Asked Questions
How does silicone mould casting compare to 3D printing?
Silicone casting produces parts in production-representative materials (not just photopolymers), with better surface finish, isotropic properties, and lower unit cost for 20+ parts. Lead time is longer (5-10 days vs 1-3 days) but results are closer to final injection-moulded parts.
Can silicone-cast parts be used for regulatory testing?
For form/fit testing and user trials, yes. For formal regulatory submissions (medical, automotive), injection-moulded parts in final production material are typically required.
Technical Specifications
Master: SLA 3D print | Mould: RTV silicone | Casting resin: PU (ABS/PC/PP/rubber-like) | Accuracy: ±0.2mm | Parts per mould: 15-25 | Lead time: 5-10 days | Batch size: 5-200 parts