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The unique iCastTM digital manufacturing process is an innovation in liquid silicone rubber (LSR) processing. Involving no tool investment, it offers a cost-effective way to develop product variations or try out different design concepts before investing in serial production tools, as well as enabling the start of pre-series and series production with small batches.


Dramatically cutting concept to production time for prototypes from a typical four and a half months to a maximum of three weeks for the average part, it helps manufacturers meet the pressures of rapidly moving markets that are demanding faster new product introductions, improvements, and advancements.


With iCastTM LSR technology, quick and multiple design iterations of components in standard industrial grade two-component platinum-cured LSR can be made. These demonstrate the properties and quality levels of high-volume injection molded parts.

iCastTM LSR – Features & Benefits:

  • New method for affordable, fast and flexible small batch production of LSR components
  • Digital manufacturing means no tool investment required
  • Parts produced have the same properties as injection molded components
  • LSR: Platinum-cured Liquid Silicone Rubber (LSR), standard industrial, medical grade, non post-cured, automotive specialized (coolant resistant), self-adhesion for overmolded two component parts
  • Tolerance levels to DIN-ISO 3302-1 M2 and ISO 3601
  • Part dimensions are typically around 55 × 55× 20 mm, with larger sizes possible depending on part geometry and design.
  • 20 to 90 Shore A hardness
  • Suitable for one to 10,000 parts
  • Surface structure
    • For two-dimensional surfaces according to VDI 3400 Ref. approx. 18 and ISO 1302 N6
    • For three-dimensional surfaces according to VDI 3400 Ref. approx. 30 and ISO 1302 N8
  • Supports large number of product variations and customized products
  • Facilitates customer’s design verification process
iCast-demo-seal

The iCast™ Process

The five-step iCastTM process utilizes digitalization and new manufacturing technologies to significantly speed up the time from enquiry to product production.

icast_Process-diagram
  1. Order Enquiry –simplified process requires submission of 3D data of part and order specifications and triggers feasibility check based on artificial intelligence (AI)
  2. Quotation - delivered within 36 hours, the quotation includes all necessary information on material and quality
  3. Order – confirmation of order according to iCastTM specifications
  4. 3D Design & Analysis – design review, feasibility check, mold layout analysis; mold flow simulation used to optimize production process
  5. Manufacturing – with additive manufacturing (AM) technology, the fully automated, digital manufacturing process reduces time and ensures high quality