1.

0 TITLE
Vacuum Casting

2.0 OBJECTIVES
1) To enhance skills in practical lab session to make the mould cavity
2) To investigate the defects of the products from vacuum casting process.
3) To study the ratio of the mixture for mould cavity.

3.0 INTRODUCTION

Vacuum casting or some called it as resin casting is a one of manufacturing process in

casting that is a moulding method for duplicate pattern by pouring liquid into a mould making
within a near vacuum tank. Vacuum casting can be categorised into two groups which is in
expendable mould casting and permanent mould casting. The different between these two groups
is the expendable mould casting cannot be reuse and the permanent can be reuse. In this
experiment, we will conduct the permanent mould casting for vacuum casting. In permanent mould
casting, liquid of mixture is poured into the mould making through gating system. Figure shown
below is a basic exposure to general way in vacuum casting. This vacuum casting greatest function
is the ability to produce precise product or pattern while reducing cost.

FIGURE 3.1

Vacuum casting needs material to make the frame or mould making. The variety of material
can be used to make the frame such as ABS-like with standard colour is beige, black, milky white
, Heat Resistant Plastic with standard colour is amber and Flame Retardant Plastic with standard
colour is milky white. In this experiment, we used silicone rubber. Some of the feature of this
material is water resistance, heat resistant and excellent chemical properties. It is widely used on
kitchen goods and packaging. Unfortunately, the silicone can withstand itself without hardener.
Hardener is material that used to harden the mixture. The composite of both mixture must follow
according with the size of frame. The industrial apparatus that used in this experiment is vacuum
oven. The function is remove air trapped in silicone mixture and compact it. If some air is still
trapped inside, some defect will happen to final product.

FIGURE 3.2

The reason why some manufacturer considers vacuum casting as their choice for make
product is silicone molding results in good quality based of surface and accuracy compared to
injection molded components. The ideal applications for this vacuum casting are pre-launch
product testing, concept model and prototypes and small series of covers and housing.
Manufacturer can used this method for prototype before officially release the product and produce
in mass production. . This makes it suitable for small-scale productions. The prototypes obtained
are effectively exact and very good condition.

FIGURE 3.3 : Final Product

4.0 APPARATUS

Figure 4.1 Oven Figure 4.2 Hardener Figure 4.3 Essil 296 Resin

Figure 4.4 Needle nose Plier Figure 4.5 Scalpel Figure 4.6 Colour

Figure 4.7 Hot Glue Gun Figure 4.8 Pattern Figure 4.9 Sheet Metal
 Figure 4.10 Tape Figure 4.11 Glove

4.1 INDUSTRIAL APPARATUS

Figure 4.1.1 Vacuum Oven

5.0 EXPERIMENTAL PROCEDURE

1. The pattern for the mould is chosen. The measurement for the mould dimension and
percentage mixture for the mould then calculated.

Figure 5.1 Figure 5.2 Figure 5.3

2. The container for the mould then be prepared using sheet metal. The sheet metal must be
cut according to the dimension that has been calculated.

Figure 5.4
3. The sheet metals then be combined using binding tape to form a frame for the mould.

Figure 5.5 Figure 5.6

4. The pattern then be combined with the pattern holder by using hot glue gun.

Figure 5.7
5. By using the mass scale, pour the mixture of the Essil 296 Resin and the Hardener
according to the calculated percentage of mixture for the mould. The mixture of the mould
then be stirred to let it mixed well.

Figure 5.8 Figure 5.9 Figure 5.10

6. The mixture then be put into the vacuum oven. The door closed tightly. Press the ‘PUMP’
button to reduce the pressure inside the vacuum oven. For the time being, the pressure will
be drop and the air trap from the mixture will be extracted. When there is air bubble on the
mixture, press ‘SLOW’ to insert the air into the oven slowly. Repeat 1 more time so that
the air bubble is no longer there. Press ‘FAST’ to insert air faster and open the vacuum
door.

7. Next, the mixture was poured into the mould frame. The pattern was set into the centre of
the frame before pouring the mixture.

Figure 5.11
8. Repeat step 6 for the mould frame.

Figure 5.12
9. The pattern then be adjusted to make sure pattern were inside the mould.

Figure 5.13
10. Insert the specimen into the oven storage. The specimen will undergo hardening process.
Wait a few days to ensure the specimen is ready.

Figure 5.14
11. After the specimen is ready, take out the specimen. Remove the specimen holder and the
sheet metal frame around the mould.

Figure 5.15
12. Line was drawn ¾ from the pattern shape. Wave line also drawn at the side of the mould.
Draw at each side.

Figure 5.16
13. The mould then be cut by using the scalper along the wave line. Then, needle nose plier
was used to separate the mould into two.

Figure 5.17
14. After the mould were cut into two, the pattern be removed from the mould. Then, combined
the two mould together again that is without pattern inside them. Stapler and binding tape
were used to combined the mould.

Figure 5.18
15. After finish combine, the scalper was used to create a bigger hole on the surface of the
mould. This is to let the pouring easy and reduce the defects.

Figure 5.19
16. The mixture for the molten plastic was prepared. Used the ratio 1:1 for the plastic and the
hardener. Add some colour to the mixture (optional). Stir the mixture.

Figure 5.20
17. The mixture then be poured into the mould. Make sure the mixture enters all over the mould
cavity.

Figure 5.21
18. After 20 minutes, remove the product output from the mould.

Figure 5.22
19. The product then be inspected for any defection and the dimension was calculated to
compare with the real pattern dimension. The percentage error then be recorded.

Figure 5.23
6.0 RESULT

Figure 6.1: Actual product

Figure 6.2: Final product

47.2mm 20mm

4mm

2.1mm

12.1mm

Figure 6.3: Actual dimension of product

47.3mm 21.1mm

4.1mm

2.1mm

12.1mm
 Figure 5: Defects on final product

6.1 SAMPLE CALCULATION

Finding the mass of mold

pwater = 1000 kg/m³

Volume = length × width × height

= 6.7 cm × 6.7 cm × 5 cm
= 224.45 cm³

𝑚𝑎𝑠𝑠
pwater =𝑣𝑜𝑙𝑢𝑚𝑒
𝑚𝑎𝑠𝑠
1000 kg/m³ =𝑣𝑜𝑙𝑢𝑚𝑒
224.45 𝑐𝑚³
Mass = 1000 kg/m³ × 1×10⁶

= 0.22445 kg
Mass of mold = Mass + 30% essil

= 0.22445 kg + 30% (0.22445 kg)

= 0.2918 kg + 10% hardener

= 0.2918 kg + 10%(0.2918 kg)

= 0.321 kg
 𝐿 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 − 𝐿 𝑎𝑐𝑡𝑢𝑎𝑙
Percentage Error for diameter, % = | |×100
𝐿 𝑎𝑐𝑡𝑢𝑎𝑙

47.3−47.2
=| |×100
47.2

= 0.21%

𝑡 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 − 𝑡 𝑎𝑐𝑡𝑢𝑎𝑙
Percentage Error for wall thickness, % = | |×100
𝑡 𝑎𝑐𝑡𝑢𝑎𝑙

4.1−4
=| |×100
4

= 2.5%

𝑡 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 − 𝑡 𝑎𝑐𝑡𝑢𝑎𝑙
Percentage Error for thickness, % = | |×100
𝑡 𝑎𝑐𝑡𝑢𝑎𝑙

21.1−20
=| |×100
20

= 5.5%
7.0 DISCUSSION

Vacuum casting is one of the other types of casting that always used in industry. The main
material is silicone as the mould making. In the process of experiment, it is easier to train for
beginner and far less dangerous during experiment. The common advantages of vacuum casting
same as other casting are dimensional accuracy, good surface finish. The advantages that can relate
with production in industry is it low processing rate. If no problem with the original pattern, the
reproduction mould will still be the same. Last advantage is good repeatability. The silicone for
mould making can use again because the detailed structure can be maintained. However, there are
some disadvantages of the vacuum casting which is high initial cost. In industry, manufacturer
always considers a manufacturing process that used low cost. Furthermore, the mould making is
too complex, take a lot of time and it became harder as the design more complex. Vacuum casting
also only suitable with industry that manufacture item in mass production. Some defect can be
seen on final product. The defect is shrinkage cavity. It is because some air is trapped inside it.
8.0 CONCLUSION

For this experiment, the objectives were archived successfully. Vacuum casting process is
the manufacturing process that very useful for plastic product. By done the experiment, it was
realized that the vacuum casting process is a suitable process that required flexible mould. Also, it
is very important to correctly calculate the percentage mixture for both silicon and hardener. This
is because the mixture will be affect the hardening of the mould. For example, the mould silicon
does not dry properly because lack of hardening liquid. Although this process cost more expensive
than metal casting, it is relatively fast prototyping and high production time frames. Nevertheless,
complexity of parts is limited and dependable wall thickness is not possible. Higher per piece costs
make vacuum forming non-competitive with other automated processes where quantities
production is larger. To be conclude, vacuum casting process are suitable process for create one
material at one time and also the finishing costs can be costly.

9.0 RECOMMENDATION

From this experiment, some recommendation can be proposed to achieve a better outcome
for student and faculty. The recommendation can be categorized for student and faculty. For
student, the first one is about the way to make the mixture of silicone and hardener. The mixture
need to be correct to get better silicone. Next, the silicone that been poured into the sheet metal
must full but not too many because when been put inside vacuum oven, it will become bubbles
and overflow from the sheet metal. For faculty, the first one is about the quality of the apparatus.
The worst apparatus in the lab is vacuum oven. The student need to forcefully closed the door
because the damage. It takes too many time and energy. Quality of apparatus are the main
recommendation that faculty can take it seriously.
10.0 REFERENCES

1. Moore, J. H. (1953). U. S. Patent No. 2,625,719. Washington, DC: U.S. Patent and Trademark
Office.

2. Smiernow, G. A. (1972). U. S. Patent No. 3,677,332. Washington, DC: U.S. Patent and
Trademark Office.

3. Yun, D. I., Sawtell, R. R., Hunt, W. H., Baumgartner, H. R., Streicher, E. T., & Ehman, M. F.
(1993). U. S. Patent No. 5,259,436. Washington, DC: U.S. Patent and Trademark Office.

4. Lecture manufacturing process notes, Dr Juri Saedon, UiTM Shah Alam.