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<p>Vacuum casting (VC) is commonly utilized for low-volume manufacturing of operational plastic parts via silicone rubber mold (SRM), which is an extremely adaptable manufacturing method capable of manufacturing parts with intricate details. In practice, VC is an eco-friendly production method because of its low energy consumption and low environmental pollution. In practice, two advantages were found. One is that the thermal expansion of molding polyurethane (PU) material after VC is a distinct phenomenon affecting dimensional accuracy. The other is that the conventional method involves matted VC parts, which are sprayed with an anti-glare mixture of ethanol and titanium oxide powder to obtain optimal measurement results in optical measurement. However, it is not an environmentally friendly method. To overcome these problems, this study proposes a method for manufacturing precision assembly parts by integrating environmentally friendly optical inspection techniques and a reinforced silicone rubber mold. It was found that the upper limit of glass microspheres, silicone carbide powder, aluminum oxide powder, and molybdenum disulfide powder added to the silicone rubber is about 19 vol%, 40 vol%, 30 vol%, and 15 vol%, respectively. The fitting accuracy and form accuracy of the VC parts were increased with the increase in the vol% of the reinforcing fillers added to the SRM. Compared to the unreinforced silicone rubber mold, the optimized composition containing 19 vol% glass microspheres improved the longitudinal and lateral fitting accuracy by up to 75% and 88%, respectively. This study demonstrates strong potential for advancing durable prototype fabrication in the rapid tooling industry. The presented approach aligns with Sustainable Development Goals 9 and 12 by promoting resource efficiency and lowering energy demand throughout the manufacturing process.</p>

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Enhancing dimensional accuracy in vacuum casting through environmentally sustainable optical measurement and reinforced silicone rubber molds

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Chil-Chyuan Kuo,
  • Heng-Qian He,
  • Wei-Cheng Wang,
  • Hong-Zhi Lin,
  • Zong-Han Yang,
  • Armaan Farooqui,
  • Song-Hua Huang

摘要

Vacuum casting (VC) is commonly utilized for low-volume manufacturing of operational plastic parts via silicone rubber mold (SRM), which is an extremely adaptable manufacturing method capable of manufacturing parts with intricate details. In practice, VC is an eco-friendly production method because of its low energy consumption and low environmental pollution. In practice, two advantages were found. One is that the thermal expansion of molding polyurethane (PU) material after VC is a distinct phenomenon affecting dimensional accuracy. The other is that the conventional method involves matted VC parts, which are sprayed with an anti-glare mixture of ethanol and titanium oxide powder to obtain optimal measurement results in optical measurement. However, it is not an environmentally friendly method. To overcome these problems, this study proposes a method for manufacturing precision assembly parts by integrating environmentally friendly optical inspection techniques and a reinforced silicone rubber mold. It was found that the upper limit of glass microspheres, silicone carbide powder, aluminum oxide powder, and molybdenum disulfide powder added to the silicone rubber is about 19 vol%, 40 vol%, 30 vol%, and 15 vol%, respectively. The fitting accuracy and form accuracy of the VC parts were increased with the increase in the vol% of the reinforcing fillers added to the SRM. Compared to the unreinforced silicone rubber mold, the optimized composition containing 19 vol% glass microspheres improved the longitudinal and lateral fitting accuracy by up to 75% and 88%, respectively. This study demonstrates strong potential for advancing durable prototype fabrication in the rapid tooling industry. The presented approach aligns with Sustainable Development Goals 9 and 12 by promoting resource efficiency and lowering energy demand throughout the manufacturing process.