Urethane Casting
Are you planning to have parts produced via injection molding but aren’t ready to commit to tooling yet? Elimold’s urethane casting service is an ideal way to produce small quantities of parts quickly for functional and cosmetic testing. Depending upon the part geometry and quantity of parts needed, it can also be faster and less expensive than additive manufacturing.
Urethane Casting Manufacturer
Urethane casting provides end-use, rigid plastic, rubber and silicone parts with production-grade quality. Elimold is a provider of professional Urethane casting services with international economic options to meet your timeline and budget. Polyurethane uses a soft tooling approach to provide professional results for low-volume production. The Urethane casting process uses a 3D printed master pattern and RTV silicone molds to provide high-quality, short-run parts up to 30 inches long. The finished dimensions of a Urethane casting depend on the accuracy of the master pattern, part geometry and casting material. As a general rule, shrinkage is typically + 0.15%.
Cast Urethane parts are ideal when color, surface quality and toughness are required for quantities from 1 to 1000 pieces. Urethane molding is a perfect alternative to insert molding or overmolding for low-volume production with a wide range of material options. Urethane or silicone casting can bridge the gap between 3D printed rapid prototyping and injection molding, balancing quality, cost and time. Urethane cast parts can be clear, color matched, painted (including EMI shielding), with mounted inserts and custom finished.
As a Urethane molding company, we understand that you need a partner who can provide the service and expertise for your critical projects. Our Urethane casting services utilize 3D printing and silicone rubber molds, keeping tooling costs low and turnaround times fast. The unique properties of many production-grade materials can be closely replicated with different polyurethane formulations. Especially when compared to plastic injection molding, Urethane casting offers numerous advantages. Plus, choosing Elimold gives you the guidance and support of dedicated designers and quality engineers, as well as fast quotes and industry-leading delivery times.
Our Capabilities
Since the polyurethane casting process begins with a 3D printed master model and utilizes silicone rubber molds, and we are well versed in a variety of different materials and formulations, no matter what custom polyurethane part or material you need, Elimold’s team of experts can meet your needs. And we can cast to a nearly unlimited thickness profile, producing parts from 0.02 inches to over 12 inches, up to 22 feet long, weighing over 500 pounds, and 8 feet in diameter.
And we also specialize in other manufacturing services, so we are the perfect choice to manufacture complex custom molded polyurethane products that are integrated into more complex parts and tooling!
From start to finish, Elimold can handle it all, making us your one-stop shop for all things polyurethane!
Urethane Casting Materials
Careful material selection is an important part of the design process. There are a wide variety of polyurethane materials that can be used in polyurethane casting. Material selection is largely determined by the physical properties desired in the final part. In addition, additives can be added to most materials to produce different colors, finishes, and textures. Elimold has hundreds of materials to choose from, covering hardness, color, and specifications. Most materials can be colored to match Pantone numbers. Here are some of the most common materials we use every day.
Shore A Elastomers
CF 50A, CF 60A, CF 70A, CF 80A, F141 40A, F190 90A, F195 95A
Rigid Urethanes
8150 HeiCast, 8400 HeiCast, IE-3075 80D, MD-50 50D, MD-60 60D, OC-5272 80D Clear, PT8902 High Impact 85D, PT8952 High Impact FR UL94V0 85D, TC-854 Nylon-Delrin Like 84D, TC-857 PC Like 84D, TC-872 70D, TC886 FR 78D, TC-891 FR 80D, TC-895 Black Hi Temp 84D, TC895 Neutral Hi Temp 85D
Silicones
TC-5050 50A, TC-5060 60A, Shin Etsu KE1310ST Tech II 40A, R220 2330 25-30A, R2364 65A, R2384 75A, R2550 53A, R2640 RP 40A
Food and Medical Grade
Steralloy 2056 55A, Steralloy 2463 80D, Steralloy 2380 85D
Surface finishing
Our team of skilled finishers and model makers carry out all finishing, painting and texturing services in-house. Secondary process treatments, including silkscreen and graphics application, enable us to provide realistic prototypes tailored to your exact requirements. The prototype will look, feel, and function as a final product. Elimold’s rigorous quality standards are upheld, and delivery schedules are maintained.
We have a wide range of additional finishing options we provide, depending on what is needed for the project:
- Spray Painting Texture / Gloss
- Logo and Graphics Application
- Electroforming Plate
- Gold Color
- Spin Line
- Sputtering
- Vacuum Metalize
In-house mold making
The molds we make are soft tools, made primarily of silicone or polyurethane, which means they are temporary molds. A standard mold can produce approximately 25 injections per cavity. Production molds can produce more parts per cavity depending on geometry, quantity, and material. For more complex parts and/or production parts, we will create a complete mold with core halves and cavity halves (similar to injection molding). Each mold is created based on the requirements of the part and project. We build single cavity, series molds, or multi-cavity molds based on the most efficient process to get your part done quickly and correctly. Here are the different types of molds we can create:
3D Printed Molds
3D printed molds are perfect when you need parts quickly, functional parts that are non-critical, non-aesthetic, and most importantly functional and delivered quickly.
Soft Prototype Mold
Soft prototype molds are the perfect choice for rapid prototyping or fast production of parts without critical requirements. It is the perfect combination of quality, fast delivery and low cost.
Soft Production Mold
Soft production tooling uses higher grade tooling materials to produce higher quality, more repeatable parts to meet critical features and tolerances. Cost and lead time are slightly longer.
Hard Production Mold
Use rigid production molds (aluminum or rigid paperboard) to achieve higher throughput and repeatable high tolerance cast polyurethane production. Cost and lead time are much higher than other options, but more parts per mold.
Get a Urethane Casting Quote
If you’re ready to start a cast urethane or silicone project, get a free quote in 24 hours or less by filling out our quick quote form.Interested in our other services? Elimold is your go-to source when it comes to 3D Printing for Prototyping and more.Our engineers will review your project and get back to you with a cost estimate and project analysis. Want to learn more? send email now！
What is Urethane Casting?
Polyurethane casting or polyurethane vacuum casting is a part casting technique used to make high-quality prototypes or parts in low volumes without any tooling cost. Rather than metal molding and tooling, the parts are made from an inexpensive silicone mold and a 3D-printed master pattern.
Urethane cast parts have exceptional surface details and cosmetic appearance, bearing a striking resemblance to the master model. The process can be likened to injection molding, where the liquid plastic resin is poured into a mold tooling and left to cool, before ejecting the solidified end part. The major difference between urethane casting and injection molding lies in the type of tooling; while injection molding uses “hard” metal tooling, urethane casting uses “soft” silicone mold tools.
Due to the nature of the materials and processes, the finished part’s dimensions might experience shrinkage. The final size is, therefore, dependent on the precision of the master model and casting material.
What are the benefits of urethane casting?
Low tooling costs
- Silicone rubber molds are created around a 3D printed model — one of Elimold’s core capabilities.
- No need for costly steel or other metal molds.
- Silicone rubber molds are created around a 3D printed
Fast turnaround times
- Elimold’s in-house capabilities mean that we control all lead times.
- Our 12-hour quoting process means no delays at any step of the way.
- 3D printed models and silicone molds can be produced in days, not weeks.
Closely reproduce the properties of other materials
- The properties of urethane allow different formulations for different properties, reducing material costs.
- Test the design and aesthetics of parts before full production runs.
- Easy color reproduction through a wide variety of paints.
Little to no finishing required
- Original 3D printed models are finished to the required specs, meaning that parts typically will not need to be finished after being molded.
- Molds are designed to minimize flash and part lines.
- Less finishing means faster delivery times.
Urethane Casting Design & Build Guidelines
Cast urethane molding is a very flexible process that can easily mold undercuts, thick sections, varying walls and parts without draft. Parts may differ depending on material, finish and geometry, but here are standard guidelines to work from:
- Minimum Wall Thickness & Features: 0.040” (1.016mm) minimum walls and 0.025” (0.635mm) minimum features. (dependent on part geometry and material)
- Standard Finish: Parts can be customized to meet your requirements for as molded or painted. (see more available custom finishes)
- Standard Lead Time: 2-3 weeks for first parts, completion depends on part, mold and material chosen. (*Parts can be delivered in as little as 1 week*)
- Tolerances: +/- 0.005” for first inch then +/- 0.003” per inch thereafter
- Parts per Mold: 25 parts per mold cavity (depending on design and material)
Is Urethane Casting Expensive?
Cast urethane molding is a relatively inexpensive manufacturing process. The lower cost is mainly due to the speed and ease of mold making for the urethane casting process. Cast urethane molding is done with silicone. The material is inexpensive, easy to work with, can quickly be modified, and will produce detailed cast urethane parts. Urethane casting can cost anywhere from a hundred to a thousand dollars depending on the complexity of the part being molded. Urethane casting is ideal for prototyping and low production runs.
Ready to Get Started?
From design to prototype and production, our team of engineers is ready to help bring your idea to life.
Common Applications of Urethane Casting
Many industries use urethane casting for their prototype and production projects. Urethane casting can be a smart choice for a lower-quantity project, as investing in injection mold tooling can be expensive. Another advantage of urethane casting is that it is optimal for use as a first production run, serving as a cost-saving measure to test prototypes before larger-scale production. Advanced prototyping is also feasible with urethane casting because the tooling and design changes cost less than other manufacturing methods. It is also possible to test various materials from a single mold. Parts made using urethane casting can also be used for customer testing, given the high aesthetic quality.
- Test Prototypes Rapid
- Prototypes Exhibit Parts
- Consumer Testing
- Products for Crowdfunding
- Lower-Volume Manufacturing
- Concept Models
- Sales Samples
- Engineering Models
- Marketing Test Samples
- Pre-Production Runs
- Bridge to Production Parts
- Point of Purchase Displays
- Conveyor Systems
- Medical Devices
- Specialty Over-Molding
- Aircraft Interior Components
Industries We Work With
Cast polyurethane molding has services and applications in nearly every industry. It’s versatile and effective! You can use polyurethane molds for prototypes, mass-produced parts, or anything in between. The following industries commonly use polyurethane casting:
Architecture and construction
- Model making
- Urban planning
- Concepts
Industrial Design & Manufacturing
- Aerospace
- Automotive
- Defense
- Industrial Equipment
- Marine and Offshore
- Oil and Gas
Medicine and life sciences
- Anatomical models
- Medical devices
- Orthopedics
- Prosthetics
- Surgical planning models
High tech, high cost
- Aesthetic and functional testing
- Concept and prototype
- Sales and marketing model
Industrial products, molds
- Jigs, fixtures and assembly tools
- Injection molding
- Silicone casting
- Sand and lost wax casting
- Thermoforming
Compared to CNC machining or injection molding
Urethane casting is faster and less expensive for the first dozen or even the first hundred components than CNC machining or injection molding. Both CNC machining from scratch and making injection molds require a lot of hands-on work by a machinist. In addition, depending on the complexity of the part and the machinery required, it can take hours to make a single part.
Urethane casting can make an entire batch of parts in the time it takes a machinist to make one part on a CNC machine.
When you pay for CNC machining, you’re paying for the expertise, the man-hours, the materials, and the machines used. With urethane casting, many of these costs disappear. In addition, the materials used for urethane casting are very inexpensive, so the choice usually has little impact on pricing.
A Low-Cost Alternative to Injection Molding
Setting up the tools and machines to injection mold parts is an expensive endeavor. If your design isn’t perfect and you’re not sure what material to use, you’re not ready for injection molding.
Before you make the decision and spend tens or even hundreds of thousands of dollars, consider polyurethane casting. This method is much less expensive but still offers the same benefits (just to a lesser degree).
The cost per unit for the first 20-30 parts will be significantly lower if you choose polyurethane casting.