Vacuum casting a small component to ±0.05 mm

Three small vacuum-cast polyurethane components in grey, clear and amber beside a coin for scale

A client challenged us to make a very small component with very tight tolerances. We did some research and accepted the challenge.

The part was to be cast in a 90 Shore A polyurethane elastomer. The tight-tolerance areas had no draft and included undercuts.

We built the master in SLA at the highest resolution we offer, and turned metal cores that sit as loose pieces in the silicone tool. The vacuum-cast parts held a diameter of 2.5 mm ±0.05 mm. We tried several techniques to get there, and we're proud to have held tolerances that tight on a vacuum casting.

Related: Vacuum casting · SLA 3D printing

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Small vacuum-cast polyurethane components beside a coin for scale