Abstract: A cast polymer integral mixing and vacuum processor system and method for delivering substantially void-free viscous polymer employs a motor connected to a mixing screw. A tube surrounds the mixing screw with one end of the tube being fixedly connected relative to the motor. The mixing screw has a thread thereon having varying pitch zones. In a loading thread pitch zone a relatively wide thread pitch is provided for receiving dry material filler at a filler input and resin at a resin input. At a first mixing and sealing thread pitch zone, a relatively narrow thread pitch is provided so as to form a vacuum seal and provide mixing of the resin with the filler material. At a void removal thread pitch zone a substantially wide thread pitch is provided and at which a vacuum tower is located in which a vacuum is maintained to remove voids formed by gas in mixed material.