Product Description

LOW VOLUME PREPRODUCTION OF COMPLEX DESIGNS
KAIAO Technicians quickly make Master Patterns and within a few days make Silicone Molds to be used for casting PU products. Compared to Plastic Injection Molding, Vacuum Casting is an Rapid Prototyping which can save time and money. The life of the Silicone Mold is directly related to the complexity of the part being cast. Silicone Molds will generally produce *5 to *0 parts before Degradation. Average cure times: (1 to 4 hours for small parts and 4 to 8 hours for big parts).


At KAIAO, innovation and creative efforts are always ongoing so that we can find better ways to improve our production processes. We believe in implementing our successful Silicone Tooling techniques and Vacuum Casting methods which are recognized by our clients.

Over Molding is an advanced process of casting around and/or through Cores that are inserted into the Cavities of Molds, resulting in the production of Individual parts made of multiple materials. Typically, a soft PU Resin is cast around and/or through a hard PU Resin to produce one part with two different Durometers and Colors. Additionally, transparent parts such as PMMA lenses can be cast directly into housings. This process allows for Hand Held products and Electronic Devices to be manufactured to meet (Vibration Minimizing, Impact Resistant, and Water Resistant) Functional Requirements.

Metal Part Inserting is a mechanical process where PU Resins are cast around and/or through Metal Parts that have been inserted into Mold Cavities to produce INMOLD ASSEMBLED PARTS. Machined Metal Parts, Stamped Metal Parts, Cast Metal Parts, as well as Brass Inserts can all be Over Molded to improve the mechanical strength, durability, and usability of parts with Functional Requirements.

Melt Molding is a special process where Cores are cast using Wax or Low Melt Temperature Alloys. These Cores are then placed inside the Mold Cavities. The Over Molded Parts are removed from the Molds with the Cores still inside. The Cores are then melted out using a heat gun and/or hot water. Through this process, complex radiator pipes and corrugated tubing can be custom manufactured.

The Coloration of Cast Parts is a creative process where Colors are added directly into the PU Resins to make INMOLD COLORED PARTS. To Achieve INMOLD Texture and Gloss, we apply 2K paint onto the surface of the Master Patterns, which is copied into the Silicone Tool, allowing for parts to be produced with minimal Post Production Finishing and are similar to Plastic Injection Molding.