Medical Dip Casting

Dip casting might be the best manufacturing method for your silicone medical device, depending on your requirements. Dip casting is ideal for forming complex shapes, ultra-thin walls, large cavities and low-durometer and low-friction surfaces, as well as medical device prototyping. The process requires special skill, and Vesta has perfected it. We recently added this capability through the acquisition of SiMatrix, who brings 15 years of industry-leading expertise in silicone dip casting.

Achieving Precision Through Dip Casting

The silicone dip casting process begins with a custom-fabricated mandrel. Our experts dip the mandrel into a silicone elastomer — sometimes several times, to achieve the required thickness — and let it cure before removing the component. The dipping technique, the viscosity and temperature of the silicone, the manufacturing environment and the curing time all factor into the quality of the finished silicone component.

Dip cast components are extremely precise because the silicone follows the geometry of the mandrel. For example, the process eliminates parting lines and allows for undercuts that would otherwise prove difficult, if not impossible, to achieve through conventional molding methods. By carefully controlling the dipping protocol, we hold wall thicknesses to extremely tight tolerances.

An Economical Solution for Medical Device Prototyping

Tooling and setup costs — for dip casting can be less than other manufacturing methods as you may avoid the need to invest in more costly steel based molds, making it a strong option for medical device prototyping — especially if your design requires multiple iterations.

An Optimal Method for Manufacturing Silicone Medical Balloons

Dip casting is the ideal method for manufacturing large, thin-walled silicone balloons. That’s because cured silicone dispersions allow for minimum vs. maximum diameters of 5:1 or more. Dip-cast silicone balloons can be used to occlude or expand tissue, or to hold a device in position. Read our silicone balloon article to help you choose the right manufacturing method for your silicone balloon — dip casting, extrusion or molding.

From Design to Medical Device Assembly

At Vesta, we truly do care for the life of your product. We offer a complete range of manufacturing and support services — from design assistance and prototyping to dip casting and medical device assembly.

Expertise in Meeting Exact Specifications

  • Wall thickness as thin as 0.002" (0.05mm)
  • Wall tolerances as tight as ± 0.002" (0.05mm) depending on part geometry
  • Flash-free components without parting lines
  • Textured, smooth or optically clear surface options
  • Prototype molding for rapid product development services
  • Laser marking