chamfer
Removes sharp edges and improves assembly feel and safety; especially recommended for parts that require frequent handling or assembly.
Polycarbonate (PC)
Polycarbonate (PC) effect resin is used in vacuum casting for functional prototypes with "higher impact resistance/higher temperature resistance," suitable for structural components requiring toughness, drop impact resistance, or certain thermal load.
Quote checklist: Upload your 3D model and, when available, a 2D drawing. Identify the required process, material, quantity, critical dimensions, finish, appearance standard, and target delivery date.
Key Material and Manufacturing Parameters
Engineering note: Values below are typical reference ranges. Final manufacturability, tolerances, material condition, surface finish, cost, and lead time depend on the drawing, geometry, quantity, and selected process.
Upload CAD files and mark critical features for an engineering review before production.
| Process | Vacuum casting (silica gel mold/Vacuum Casting) |
|---|---|
| Material | Polycarbonate (PC) (vacuum casting system, aiming to achieve a molding solution close to the appearance and feel of PC) |
| Typical accuracy | ±0.20 mm (common reference; it is recommended to mark the tolerance or note "precision first" for key holes/mating surfaces) |
| Minimum wall thickness | ≥1.0 mm (recommended; risks of outgassing, shrinkage and deformation need to be assessed for thin walls/large flat surfaces) |
| Transparent/Translucent | Assessable (structure and process are sensitive; it is recommended to choose a polishing/spray coating solution and clarify appearance standards) |
| Strength and toughness | More interested in "injection molding feel" and functional validation; in long-term high load/high fatigue scenarios, it is recommended to switch to injection molding or CNC |
| Service temperature | Evaluate based on the specific molding system and usage conditions (if you are close to a heat source, please note the operating temperature and duration) |
| Finishing | Chamfering, grinding, bonding, screen printing, laser engraving, painting, polishing (transparent edge) |
| Typical lead time | Related to structural complexity, quantity, mold splitting plan and finishing; clear delivery and expedited options will be given after uploading the file |
Finishing
polish
Improve parting lines, gates and small corrugations; the appearance surface can be finely polished according to standards to improve consistency.
bonding
Suitable for structural assembly after separate parts are copied; it is recommended to reserve space for positioning and glue joints in the design, and indicate strength/appearance priority.
screen printing
Suitable for logos, scales, logos and other graphic information; it is recommended to provide vector files and location and size instructions.
Laser engraving
For use with durable markings and serial numbers; clear zone, font height, and contrast goals recommended.
spray paint
Achieve opacity/specified color and uniform texture (matte/high gloss); spray coating solution is recommended when high appearance consistency requirements are required.
Polished (transparent edge)
Used to improve the light transmission performance of transparent or translucent areas; it is recommended to define the "transparent window/transparent edge" range and appearance standards in advance.
Why choose polycarbonate-PC (vacuum casting)
Smaller batches are more cost-effective
Compared with injection molding, the mold opening threshold is lower, and it is suitable for trial production, verification and small batch delivery of 10-200 pieces.
The appearance and feel are closer to the finished product
It is easier to obtain a look and feel close to that of plastic parts, which is suitable for review, display and functional validation.
Rich finishing options
Supports painting, screen printing, laser engraving, etc., making the sample closer to the "deliverable appearance standard".
The transparent edge effect can be evaluated
For structures that require transparent/translucent edges, polishing (transparent edges) can be used to optimize the visual effect (needs to be combined with structural evaluation).
Recommended Applications
- Low-Volume Production: Product iteration stage, small batch trial sales, small batches of spare parts
- Appearance review: It requires painting, screen printing, laser engraving, etc. to get close to the finished product effect.
- Functional validation: Requirements for toughness, assembly inspection and structural validation are required
- Transparent/translucent requirements: Clear edge polishing or clear area options can be evaluated
It is not recommended to use it directly (it is recommended to change the process)
- Long-term high load/high fatigue: Injection molding or CNC is recommended (material and structure are more controllable)
- Extremely strict tolerances: Recommended injection molding + precision mold or CNC secondary processing solution
- Extremely heat/chemical resistant: Please provide working conditions to evaluate a more suitable material system.
- Oversized parts or complex parts with deep cavities: It is necessary to evaluate the risks of mold parting, exhaust and pouring, and change the process if necessary.
Design and DFM Guidelines
- Uniform wall thickness: Vacuum casting is sensitive to sudden changes in thickness, so try to avoid thickness jumps; large flat surfaces can be reinforced to reduce the risk of deformation and shrinkage.
- Parting line and gate location: Please define the appearance surface in advance. We will try our best to move the parting line/gate to the non-appearance surface during the manufacturability evaluation.
- Exhaust and deep cavity structure: Deep cavities, blind holes, and slender channels are prone to trapping air and causing bubbles; it is recommended to optimize the exhaust path or adjust the structure.
- Assembly holes and mating surfaces: It is recommended to provide 2D markings for key holes/locating surfaces; leave a margin and use secondary processing/assembly compensation if necessary.
- Bonding assembly: If bonding is required, it is recommended to reserve space for positioning steps/tongues and glue joints, and state "strength first" or "appearance first".
- Transparent/Translucent Target: The transparency effect is greatly affected by the structure, pouring and finishing; it is recommended to clearly define the scope of the transparent area, and accept a certain texture/slight ripple or use spray coating instead.