In the automotive industry, every component tells a story. A slim reflector on a bumper, a steering-wheel switch pack, a discrete sensor housing, or a precision bracket, none of these parts are glamorous on their own, but together they shape how a vehicle feels, performs, and keeps people safe.
At 3D Vector, we help automotive teams bring these parts to life quickly and accurately using vacuum casting. From early design validation to low-volume production, our vacuum-cast components give OEMs and tier suppliers a fast, reliable way to bridge the gap between 3D CAD data and road-ready parts.
The parts shown in the images on this page, black brackets, sensor housings, switch modules, reflectors, and light guides were all vacuum cast in our facility for a leading automotive client. They demonstrate what’s possible when you pair smart design with the right manufacturing partner.
What is vacuum casting?
Vacuum casting is a versatile low-volume manufacturing process that uses silicone molds and polyurethane resins to reproduce highly detailed plastic parts. It’s ideal when you need components that look and function like injection-moulded parts, but you don’t yet want to invest in hard tooling.
The typical workflow at 3D Vector looks like this:
- Master pattern: We begin with a master model, usually 3D printed with high-resolution SLA or machined from plastic or aluminium. This part is carefully finished to the exact texture and gloss you want on your final component.
- Silicone mould creation: The master is suspended inside a mould box and encapsulated in liquid silicone. Once the silicone cures, we cut it open along a planned parting line and remove the master, leaving a cavity that mirrors your design down to the smallest detail.
- Casting under vacuum: A specially selected polyurethane resin is mixed and degassed, then poured into the mould under vacuum. This step removes air bubbles, ensuring crisp edges, clean surfaces, and consistent mechanical properties.
- Curing and demoulding: The filled mould is cured in a temperature-controlled oven. After curing, the part is removed and trimmed, ready for finishing.
- Finishing and assembly: Depending on your project, we can paint, tint, polish, texture, engrave, or assemble parts, so what you receive is as close as possible to your intended production part.
A single silicone mould typically yields 15–30 shots, sometimes more for simple geometries. This makes vacuum casting perfect for prototype builds, alpha and beta test runs, show cars, service parts, and niche-volume components.
Why vacuum casting works so well for automotive projects
Automotive development is under constant pressure: shorter programmes, tighter budgets, and rising expectations for fit, finish, and performance. Vacuum casting helps engineering and purchasing teams meet those pressures by delivering:
1. Production-like parts without production tooling
Before committing to steel moulds, you need to be confident in your design. Vacuum-cast parts closely mimic injection-moulded components in:
- Surface finish and gloss
- Wall thickness and detail
- Dimensional accuracy
- Functional performance (snap-fits, clips, threads, bosses, etc.)
This allows your design, test, and styling teams to evaluate a part as if it came straight from production, but weeks earlier and at a fraction of the tooling cost.
2. Rapid turnaround for fast-moving programmes
With no steel tooling to cut, lead times shrink dramatically. Once we receive your final CAD:
- Masters are produced and finished in days
- Silicone moulds follow shortly after
- First off-tool parts can be in your hands in as little as 1–2 weeks, depending on complexity
That speed makes a huge difference when you’re trying to hit a design freeze, get parts ready for a show car, or keep a development fleet on the road.
3. Flexible materials for real-world testing
At 3D Vector, we work with a wide range of casting resins to simulate:
- Rigid ABS-like plastics for brackets and housings
- Tough, impact-resistant materials for interior trim and handle components
- Flexible or rubber-like materials for gaskets, seals, and protective parts
- Optical-grade clear or tinted materials for light guides and reflectors
This flexibility means you can run ergonomic tests, assemble parts onto vehicles, validate mounting strategies, and even conduct limited functional testing long before production tools are cut.
4. Cost-effective low-volume production
Not every automotive component justifies a full injection-moulded tool. For special editions, motorsport applications, aftermarket accessories, or legacy service parts, vacuum casting is often the most economical route.
You benefit from:
- Minimal upfront tooling cost
- The ability to update designs between mould batches
- Predictable, repeatable quality across small runs
Real automotive parts, vacuum cast by 3D Vector
The parts are a snapshot of what we produce every day for automotive clients. Here’s how they fit into typical projects:
Precision brackets and mounting hardware
The slim black component with multiple holes and slots is a good example of a vacuum-cast mounting bracket. Parts like this are often used to locate sensors, small control modules, or trim pieces behind the scenes.
Key requirements for these components are dimensional stability, hole position accuracy, and clean edges so they interface correctly with surrounding parts. By combining a high-resolution master with controlled casting and post-machining where needed, we deliver brackets that bolt up perfectly in real vehicles.
Structural carriers and covers
The intricate black frame with vertical openings illustrates how vacuum casting can handle complex geometries. Automotive teams use similar parts as carriers for vents, electronics, or decorative trim.
Thin ribs, undercuts, and small cut-outs are all reproduced accurately in silicone moulds, making vacuum casting ideal for these lightweight structural components.
Cylindrical housings and threaded features
The cylindrical black housing with multiple circular openings shows that even robust, load-bearing parts can be vacuum cast. For this project, we reproduced:
- Internal threads for fasteners and caps
- Concentric diameters for tight fits
- External geometry with chamfers and fillets designed to sit inside a larger assembly
By carefully controlling material choice and mould design, we can deliver housings that stand up to real installation and functional testing.
Interior switchgear and control modules
One of the most recognizable pieces in the set is the curved black switch pack, similar to those found on steering wheels or door trims. For these components, look and feel are everything:
- Button travel must be consistent
- Symbols and legends need to be sharp and durable
- The overall assembly has to match the surrounding trim in colour and gloss
We achieve this by combining vacuum-cast bodies with insert-moulded or pad-printed details, giving your design and UX teams production-representative parts for reviews, clinics, and show vehicles.
Reflectors and light guides
The long red reflector and the turquoise light bar highlight one of vacuum casting’s biggest strengths: optical components.
Using clear polyurethane resins and polished masters, we produce lenses and light guides that:
- Transmit light effectively
- Maintain sharp edges and consistent wall thickness
- Can be tinted to your exact colour requirements
These parts are perfect for validating lighting concepts, integrating LEDs, checking light distribution, and building full vehicle demonstrators.
Our process: From CAD to finished part
At 3D Vector, we see ourselves as an extension of your engineering team. A typical automotive vacuum-casting project with us looks like this:
- Project discussion: You share your CAD files, target quantities, timeline, and functional requirements. We suggest the best combination of materials, master-making method, and finishing approach.
- Design for manufacturability (DFM) review: Our engineers review your files for thin walls, undercuts, draft, and assembly issues. Wherever needed, we propose minor design tweaks to improve mould life, part quality, and consistency.
- Master production and sign-off: Masters are 3D printed or machined, then finished to your specified texture and gloss. If required, we send photos or sample parts for approval before moulding.
- Mould making and casting: We produce silicone moulds and cast the required quantity of parts, monitoring every batch for consistency.
- Finishing, painting, and assembly: Parts are deburred, painted, printed, tinted, or assembled according to your brief. Each project includes a tailored inspection plan to ensure quality.
- Packaging and shipping: Finished components are carefully packaged and shipped to your facility, ready to go straight into builds, rigs, or customer vehicles.
Why automotive teams choose 3D Vector
There are many companies offering vacuum casting – so why partner with us?
- Automotive experience: We understand the pressures of vehicle programmes: tight gates, global teams, and immovable launch dates. Our workflows are built to support that reality.
- Attention to detail: From tiny alignment features to subtle surface textures, we know that small details can make or break assembly. The components in your images demonstrate the level of finish we deliver every day.
- End-to-end capability: With in-house 3D printing, machining, casting, and finishing, we control the entire process, keeping communication simple and timelines tight.
- Flexible volumes: Whether you need a handful of parts for a rig or a few hundred components for a pilot build, we scale to match your requirements.
- Confidentiality and reliability: We regularly work with sensitive designs and pre-launch vehicle platforms. Your IP is handled securely and professionally from first contact to final delivery.
The automotive components started as CAD files and design sketches. Through careful engineering, vacuum casting, and finishing, they became real parts that could be handled, tested, installed, and driven.
Ready to bring your next automotive project to life?
If you’re working on a new vehicle platform, a facelift programme, an aftermarket accessory, or a limited-run special, vacuum casting may be the fastest and most cost-effective way to get high-quality parts into your hands.
At 3D Vector, we’re ready to support you with:
- Rapid prototypes that look and feel like production
- Low-volume runs for show cars, tests, and niche vehicles
- Clear lenses, reflectors, and light guides for innovative lighting concepts
- Functional brackets, housings, and switchgear for complete assemblies
Share your CAD files and project requirements with us, and let’s turn your next idea into reality.