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Advanced Plastic Components Aerospace Applications Vacuum Casting Polycarbonate PEEK Strong and Lightweight Parts
Product Description:
In the furniture industry, the production of durable, aesthetically pleasing components is essential for creating high-quality products. Vacuum casting is an effective method for producing precise, durable, and lightweight plastic parts for furniture, such as table legs, handles, and structural supports. Polyurethane and ABS are popular materials used in furniture component manufacturing due to their strength, flexibility, and ability to be molded into complex shapes.
Polyurethane is a versatile material that can be cast into various densities and hardness levels, making it suitable for producing flexible or rigid parts. It is commonly used for furniture components that require cushioning, like armrests or chair pads, as well as for decorative items such as table bases or drawer pulls. ABS, known for its impact resistance and dimensional stability, is used in furniture for structural parts like table legs, cabinet supports, and handles that need to maintain strength under pressure and frequent use.
The vacuum casting process begins with the creation of a master model, which can be made through 3D printing or CNC machining. This model is used to create a silicone mold, which captures all the fine details of the furniture component design. Liquid Polyurethane or ABS resin is injected into the mold under vacuum conditions, ensuring that the resin fills every cavity and produces high-quality parts with smooth surfaces and accurate dimensions.
The key advantages of using vacuum casting for furniture components include the ability to rapidly prototype new designs, customize parts for specific furniture pieces, and produce small batches of custom
.
Applications of vacuum casting
Vacuum casting is one of the most cost-effective ways to produce high quality, low volume plastic parts which can be similar to injection moulding parts
The parts are especially suitable for form, fit and function tests during the embodiment design stages, where they can be used for marketing, field user testing and product design verification purposes
There are many Urethane casting resins commercially available that can be used to create parts to satisfy a wide range of design requirements such as temperature requirements, different surface textures, hardness, etc.
Materials are also available to create parts that are fully opaque, translucent or completely transparent
Sometimes high-quality wax masters can be made using vacuum casting for investment casting to increase the finer details of intricate features
| Time frame | Within 24 hr – 5 working days for up to 30-50 parts |
| Material choice | Wide variety of materials available |
| Accuracy | ±0.3% (with a lower limit of ± 0.3 mm on dimensions smaller than 100 mm) |
| Minimum wall thickness | To ensure that the mould is filled properly, a wall thickness of at least 0.75 mm is necessary. But best results are achieved with a recommended wall thickness of 1.5 mm |
| Maximum part dimensions | The size of the mould is limited by the dimensions of the vacuum chamber |
| Typical quantities | Up to 50 parts per mould |
| Surface structure | Gloss to Matt surface finish can be obtained |
Polyurethane (PU), the full name of polyurethane, is a polymer material formed by polyol and polyisocyanate through polycondensation reaction with excellent mechanical properties
[1], which is extremely plastic. Its synthesis can be traced back to 1937, when Professor Byaer first synthesised straight-chain linear polyurethane resins using 1,6-hexanediisocyanate and 1,4-butanediol as raw materials
[2]. Several major classifications of polyurethanes include polyether-type, polyester-type, polyimide-type, and polyurea-type, etc. They can be made into materials such as polyurethane plastics (mainly foams), polyurethane fibres (known as spandex in China), polyurethane rubbers and elastomers
[3].After nearly eighty years of technological development, this material has a wide range of applications involving products such as coatings, adhesives, fabric finishes, leather modifiers, polyurethane soft/rigid foam, elastomers, etc., which are used in the fields of textiles, construction, aviation, shipping, transportation, medicine, electronics, and so on.
Flexible polyurethane mainly has a linear structure with thermoplasticity, which has better stability, chemical resistance, resilience and mechanical properties than PVC foams, with less compression variability. Heat insulation, sound insulation, shock resistance, anti-virus performance is good. Therefore, it is used as packaging, sound insulation and filtration materials. Rigid polyurethane plastic is lightweight, sound insulation, superior thermal insulation performance, chemical resistance, good electrical properties, easy processing, low water absorption. It is mainly used in construction, automotive, aviation industry, thermal insulation structure materials. Polyurethane elastomer performance between plastic and rubber, oil resistance, abrasion resistance, low temperature resistance, aging resistance, high hardness, elasticity. It is mainly used in the shoe industry and the medical industry. Polyurethane can also make adhesives, coatings, synthetic leather, etc.
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