TABLE OF CONTENTS
TABLE OF CONTENTS ........................................................................................................ 1
LIST OF FIGURES ................................................................................................................. 2
LIST OF TABLES ................................................................................................................... 2
1.0 OBJECTIVES .................................................................................................................... 3
2.0INTRODUCTION (THEORY AND BACKGROUND).................................................. 4
3.0 LIST OF APPARATUS/MATERIALS/EQUIPMENT.................................................. 5
4.0 SAFETY AND EXPERIMENTAL PROCEDURE ........................................................ 6
5.0 RESULT AND DATA ANALYSIS .................................................................................. 7
6.0 DISCUSSION OF RESULTS ........................................................................................... 8
7.0 CONCLUSION .................................................................................................................. 9
8.0 RECOMMENDATION ................................................................................................... 10
9.0 REFERENCES................................................................................................................. 11
APPENDICES ........................................................................................................................ 12
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LIST OF FIGURES
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LIST OF TABLES
No table of figures entries found.
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1.0 OBJECTIVES
1. To create a 3D-printed pattern.
2. To fabricate a silicone mold using vacuum casting techniques.
3. To measure and analyze the accuracy of the prototype produced with the original
drawing and the 3D-printed pattern.
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2.0 INTRODUCTION (THEORY AND BACKGROUND)
BACKGROUND STUDIES
2.1 Rapid Prototyping Overview
Rapid prototyping refers to a group of techniques used to quickly fabricate a
scale model of a physical part. Some techniques are often used in the industry nowadays,
such as 3D printing and vacuum casting, to replicate some ideas during the development
process. It allows engineers and manufacturers to examine and evaluate multiple design
options effectively while gathering feedback to improvise the available design before
committing to the production line. These techniques are commonly used, as they are
more cost-effective compared to traditional prototyping methods. These techniques
help engineers and designers detect any flaws in the design and enable people to
experiment and explore many design options, leading to higher-quality products.
Figure 2.1.1: Rapid Prototyping process
2.2 Methods used in Rapid Prototyping
3D printing is a process of layering a designated material to build up and create
a 3D part. This method belongs to additive manufacturing. This process is the opposite
of subtractive manufacturing, where final products are produced after removing parts
from a larger block of material (TWI Ltd., 2025). The materials that can be printed
using a 3D printing machine are conventional thermoplastics, ceramics, graphene-
based materials and metal. This technology has the potential to revolutionize and
upgrade the industries in the long run. As mentioned before, this technology will
eventually increase the production speed, reduce cost and change the logistics of the
company. The company can manage the entire process of the product based on
customer needs efficiently (N. Shahrubudin, 2019).
Vacuum casting uses a vacuum to replicate liquid material into a silicone mold
to create the parts. The liquid material often used in this manufacturing process is resin.
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This kind of process is often used in the manufacturing industry because it is cost-
effective and easy to replicate. The vacuum process offers high detail and accuracy as
it ensures that the resin fills into the details and geometries of the mold. It is an
important tool to make prototypes that are like injection-molding parts, which can be
used for testing before mass production. A wide variety of resins can be used in vacuum
casting, making it a very flexible process that will help engineers and designers refine
the designs before mass production. However, this process still has its limit where it
will reduce dimensional accuracy that needs to be controlled during the fabrication
phase (Manon Bouriaud, 2025).
Figure 2.2.1: 3D printing and Vacuum casting method of working
THEORY
2.3 3D Printing Mechanics
Rapid prototyping techniques like 3D printing follow the layer-by-layer
material decomposition theory. 3D printing depends on a few processes, including
Fused Decomposition Modelling (FDM) and Stereolithography (SLA). FDM is a 3D
printing process that extrudes thermoplastic filament layer by layer to create three-
dimensional objects. A CAD model is used to guide and control the extrusion of melted
plastic through a nozzle, starting from the base up until the top of the object (Acierno,
D., & Patti, A., 2023). On the other hand, SLA is a resin-based 3D printing technology
that uses a laser to cure liquid resin into hardened plastic to create 3D objects. This
process offers high accuracy, fine details and a smooth surface (Formlabs, 2025).
2.4 Vacuum Casting Mechanics
Vacuum casting follows the principles of fluid dynamics and polymer science.
Darcy’s Law explains the fluid flowing through porous mold, relating the flow rate to
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the pressure gradient and permeability of the mold (Whitaker, 1986). This law describes
resin flow through silicone molds under vacuum pressure to ensure the cavity fills with
the resin by removing air pockets. These theoretical foundations allow vacuum casting
to produce prototypes with details following controlled dimensions.
Figure 2.4.1: 3D printing mechanism
Figure 2.4.2: Vacuum casting mechanism
2.5 Metrology
Metrology, the science of measurement, is integral to ensuring the quality and
functionality of manufactured products. Accurate measurements are critical for quality
control, assembly, and performance, impacting the overall success of manufacturing
processes. Tools such as callipers, micrometres, and coordinate measuring machines
(CMMs) are commonly employed in metrology to verify that products meet specified
tolerances.
The interrelationship between rapid prototyping and metrology is vital in modern
manufacturing. Rapid prototyping serves as the medium to replicate and turn any ideas
and designs into physical products, while metrology ensures that the final products
adhere to quality standards and precise specifications. This feedback loop—where
measurements inform adjustments in design and machining parameters—highlights the
importance of integrating these components for optimal manufacturing outcomes.
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3.0 LIST OF APPARATUS/MATERIALS/EQUIPMENT
There is a list of apparatus that has been used for rapid prototyping labs depending on the
processes:
Table 3.1: List of Apparatus
Process List of Apparatus
i. 3D Printer
ii. Polylactic Acid (PLA) Filament
iii. CATIA Software
3D Printing
iv. Slicing Software (Ultimaker Cura)
v. Laptop
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i. Silicone Rubber
ii. Casting Resin
Vacuum Casting
iii. Vacuum Chamber and Pump
iv. 3D Printed Pattern
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i. Coordinate Measuring Machine (CMM)
ii. Engineering Drawing with Specifications
iii. Vernier Caliper
Metrology
iv. Horizontal Profile Projector
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4.0 SAFETY AND EXPERIMENTAL PROCEDURE
SAFETY PROCEDURES
To prevent any unwanted accidents from occurring during experiments that cause injury to
someone, safety precautions should be emphasized. There are safety procedures that must be
taken into account during the experiment:
Phase 1: 3D Printing of the Pattern
Table 4.2: Safety Procedures for 3D Printing of the Pattern
• Wear safety glasses and heat-resistant gloves.
• Make sure the printer is placed on a stable and ventilated surface.
Before Printing
• Make sure the body is free from wearing jewellery or anything
that could cause injury.
• Monitor the printer for filament jams or misprints to avoid
During Printing overheating or fire hazards.
• Do not touch the hot nozzle or print bed.
• Wait for the hot nozzle and print bed to cool down completely
before removing it from 3D printer.
• To avoid scratches or injuries, remove prints using non-metallic
equipment such as plastic scraper spatula as shown in Figure 4.1.
After Printing
Figure 4.1: Plastic Scraper Spatula
• Turn off the 3D printer when not in use.
Phase 2: Vacuum Casting
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Table 4.3: Safety Procedures for Vacuum Casting
• Wear appropriate personal protective equipment (PPE) such as
chemical resistant gloves (Figure 4.2), lab coat and safety
goggles.
Before Casting
Figure 4.2: Gloves
• Inspect the pump and vacuum chamber for leaks or damage.
• Avoid direct skin contact when handling casting resins and
silicones which can cause skin irritations and allergic reactions.
• Use specialised tools while handling any chemicals such as
plastic mixing cups as shown in Figure 4.3.
During Casting
Figure 4.3: Plastic Mixing Cups
• Spills should be cleaned right away using the proper solvents.
After Casting • Unused silicone and resin should be carefully labelled, sealed,
and stored.
Phase 3: Metrology and Comparison
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Table 4.4: Safety Procedure for Metrology and Comparison
• Wear personal protective equipment (PPE) such as lab coat.
Before • Make sure all machines and measuring equipment such as
Measurements Coordinate Measuring Machine (CMM), vernier caliper and
Horizontal Profile Projector is calibrated and set up correctly.
• Avoid placing any objects on the measuring surface that could
interfere with the procedure.
• Make sure only one person operates the measuring tool or
machine at a time as shown in Figure 4.4.
During
Measurements
Figure 4.4: Correct way to operate the machine
• When operating the CMM, avoid moving the object being
measured while the measurement procedure is in progress
• Turn off the measuring tools and machines.
After Measurements • Make sure the data is recorded correctly and clearly to avoid
errors in analysis.
EXPERIMENTAL PROCEDURE
Phase 1: 3D Printing of the Pattern
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1. 3D model has been prepared using CATIA software as shown in Figure 4.5. Our 3D model
is key shaped as shown in Figure 4.6.
Figure 4.6: Key Shape in CATIA
Figure 4.5: CATIA Software
Software
2. 3D model was transferred from CATIA software to Ultimaker Cura to sliced it by using
SD card.
3. The sliced file was exported, and printing began using a 3D printer where the object’s
printing material was polylactic acid (PLA) filament so that a real 3D model is created as
shown in Figure 4.7. Figure 4.8 shows a key shaped model print; the progress of the printing
appeared on the Creality Ender 3 3D Printer as shown in Figure 4.9.
Figure 4.7: 3D Model Figure 4.8: Printed Model
Figure 4.9: Creality Ender 3 3D Printer
Phase 2: Vacuum Casting
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1. Measuring (Figure 4.10), bending (Figure 4.11), cutting (Figure 4.12) and joining activities
were carried out to build the mould box.
Figure 4.10: Measure Figure 4.11: Bending
Figure 4.12: Cutting
2. Silicone and curing agent are mixed and weighed according to the size of the 3D printed
pattern according to the manufacturer’s ratio as shown in Figure 4.13.
Figure 13: Mixture of silicone base and curing agent
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3. To eliminate air bubbles, the silicone and curing agent mixture is placed in a vacuum
casting machine for 1 to 2 minutes as shown in Figure 4.14. Then, pour that mixture into
the mould box that containing of 3D printed pattern as shown in Figure 4.15.
Figure 4.14: Vacuum Casting Machine Figure 4.15: Pouring a mixture
4. To allow it to solidify, the mould box containing the mixture and the 3D-printed pattern is
placed into a vacuum chamber as shown in Figure 4.16, where it can ensure that the mixture
remains at room temperature for a day.
Figure 4.16: Vacuum Chamber
5. The silicone mould is cut open carefully to remove the 3D printed pattern, where that cavity
produced is used for casting as shown in Figure 4.17. Then, close the mould cavity again
well and neatly as shown in Figure 4.18.
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Figure 4.17: Cavity produced Figure 4.18: The prepared mould cavity
6. To create the prototype, the two components of casting resin are mixed and poured into the
silicone mould cavity through the sprue slowly, as shown in Figure 4.19. Next, immediately
place it back into the vacuum casting machine a second time for 1 to 2 minutes to remove
any air trapped on it. After that placed
Figure 4.19: Pour the casting resin into the silicone mould cavity
7. Let the resin harden at room temperature for a certain period of time. Then, remove the
fully hardened resin from the silicone mould cavity carefully to avoid breaking it as shown
in Figure 4.20. Trim off any excess resin as a finishing touch as shown in Figure 4.20.
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Figure 4.20: A process to remove Figure 4.21: Excess resin
hardened cavities
Phase 3: Metrology and Comparison
1. If necessary, set up the machine or measuring devices.
2. Measure the prototype as shown in Figure 4.15 and compare the three types of measurement
techniques dimensions with the original drawing.
Figure 4.22: Prototype dimensions
3. For analysis, record the measurements, deviations, and comments.
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5.0 RESULT AND DATA ANALYSIS
Position Process Current Original Error (%)
product value product value
(mm) (mm)
Original
Drawing
3d Printed
A
Pattern
Vacuum Cast
Prototype
Original
Drawing
3d Printed
B
Pattern
Vacuum Cast
Prototype
Original
Drawing
3d Printed
C
Pattern
Vacuum Cast
Prototype
Original
Drawing
3d Printed
D
Pattern
Vacuum Cast
Prototype
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CMM measurement
Profile Projector measurement
Vernier Calliper Measurements (Vacuum cast prototype) (mm)
Vernier Calliper Measurements (3d printed pattern) (mm)
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6.0 DISCUSSION OF RESULTS
Based on the product that has been obtained in the phase 1 procedure, which is the 3D
printed key model, it shows that the product has a small defect at the tip of the key model which
makes the model become slightly slanted. This may be due to thermal deformation that occurs
during the printing process. The thermal deformation that happens in this is involved with the
cooling of the first layer of the model, which causes the bottom layer to shrink and slightly
warp upward. Then as the next layer of the model is applied, it will only refer to the earlier
setup coordinate and not the coordinate after the warping happens. Later, the result of the model
will become thinner compared to the actual model in the software. In order to prevent this
warping phenomenon during the printing process, the model must be printed with a brim at the
first layer of the model so that it can prevent the model from being lifted during the whole
process. The surface finish of the 3D printed model is also not very smooth, this may be caused
by low resolution settings in the Catia model which make the model become rough based on
the filament lines. There are also some incomplete fused filaments at the side of the model
which are possibly caused by the 3D printer nozzle not being hot enough while printing this
part.
Figure: Thermal deformation of 3D printed model
Next, in phase 2 which is the preparation of the mold for the vacuum casting process,
there are some mistakes that happen while the process of eliminating the air bubbles in the
silicone mixture, which the silicone mixture raises and overflowing out from the bottle that has
been cutted. This happens because the bottle that has been used is not deep enough to prevent
the silicone mixture from overflowing. Therefore, the silicone mixture that has been prepared
becomes lesser than the intended volume based on our mould box capacity which causes the
mould box cannot be fully filled with the silicone mixture. As a result, the mold becomes
thinner at the top side where the model is close to the surface of the mold. After the mold
solidifies in the vacuum chamber, the model has been taken out in order to proceed to the next
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step which is pour the casting resin into the mould. During the pouring process, everything
went smoothly as the resin flowed in every edge of the mould and rose through the air hole of
the top mould which meant there was no air trapped during the process. However, there were
some air bubbles trapped in the mould at the tip of each cut of the key product. This air bubbles
effect can be avoided by lifting up a bit the mold at the part opposite the key cut. Therefore the
resin will fully fill the tip of the key cuts first and give access to the air bubbles to be removed
from the mold.
Figure: Air bubbles defect on harden resin product
The dimensions of both products are measured using three different equipment which
are Coordinate Measuring Machine (CMM), vernier caliper and Horizontal Profile Projector
(HPP). The measurements from all equipment are also different in terms of accuracy, although
the measured product is the same. Based on the overall analysis of both products' dimensions,
it shows that the product from the hardened resin is more accurate to its original dimensions in
Catia software compared to the 3D printed product. This may be caused by the hardened resin
having a slightly larger dimension throughout the mold prepared and the expansion. Then for
the 3D printed product dimension, the result already contains errors in terms of accuracy that
may be caused by many factors which is the 3D printer itself. Therefore, as the hardened resin
has expanded a little bit, it makes the product more accurate. Based on the measurements
obtained from all the three equipment, it can be concluded that the CMM gives the most
accurate results with less possibility of human error involved compared to the HPP and vernier
caliper. This is because HPP and vernier calipers involve a lot of human interference in order
to measure and read the data, which increases the possibility of measurement errors.
7.0 CONCLUSION
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8.0 RECOMMENDATION
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9.0 REFERENCES
1. Domenico Acierno, A. P. (2023). Fused Deposition Modelling (FDM) of Thermoplastic-Based Filamen
Materials.
2. Formlabs. (2025). Retrieved from Guide to Stereolithography (SLA) 3D Printing: [Link]
printing/
3. Manon Bouriaud, C. R. (2025, May 19). Vacuum Casting: Process, Applications & How It Compares. Re
casting-overview/#:~:text=Vacuum%20casting%20involves%20pouring%20liquid,compares%2
4. N. Shahrubudin, T. L. (2019). An Overview on 3D Printing Technology: Technological, Materials, a
Retrieved from [Link]
5. Personal Protective Equipment - Overview | Occupational Safety and Health Administration. (2025)
equipment#:~:text=Personal%20protective%20equipment%2C%20commonly%20referred,mech
7. TWI Ltd. (2025). What is 3D Printing? - Technology Definition and Types. Retrieved from [Link]
printing
8.
What is PLA? (Everything You Need To Know). (2017). [Link]. [Link]
9. Whitaker, S. (1986). Flow in porous media I: A theoretical derivation of Darcy's law. Transport in Poro
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APPENDICES
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