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Urethane Casting Prototypeing Service

Custom production-quality prototypes and parts with unlimited design complexity, including internal angles that cannot be achieved with CNC machining, and slopes and wall thicknesses that cannot be achieved with injection molding.Let's get started. The fastest delivery time is 5 working days. If you have special requirements, please contact us to speed up urethane casting production.

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Parts delivered in as fast as 5 days

Infinite complexity and high-precision details

Part inspection reports included with every order

Rapidly produce 1-50 prototypes. Shorten the gap between prototype and final part

To help you get an idea of ​​our urethane casting capabilities, here are some of our urethane casting prototype projects. kprototype caters to all types of urethane casting prototypes and final parts. So if you are looking for a urethane casting prototype and parts production company for your project, you don’t need to look anywhere else!

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What is the Polyurethane Casting?

Polyurethane casting is a process used for rapid prototyping and low-volume production. First, a master model is created using 3D printing or CNC machining, from which a silicone mold is then made. Liquid polyurethane resin is poured into the silicone mold, usually under vacuum to remove air bubbles and ensure a smooth, defect-free casting. Once the resin cures, it is removed from the mold and finished with subsequent trimming. This process accurately replicates the details of the master model and is suitable for making functional parts that look realistic and perform like injection molding. Polyurethane casting is widely used for prototyping and low-volume production because of its speed, low cost and flexibility.

Cast polyurethane parts are ideal when color, surface quality, and toughness are required for quantities from 1 to 100 pieces. Polyurethane molding is a perfect alternative to insert molding or overmolding for low volume production with a wide range of material options. Polyurethane or silicone casting can bridge the gap between 3D printing rapid prototyping and injection molding, balancing quality, cost, and time. Polyurethane cast parts can be clear, color matched, painted (including EMI shielding), with mounted inserts, and custom finished.

Service:

Production quantity:
Prototyping: 1-100 pieces
Low volume: 101-10,000 pieces
High volume: 10,001 pieces and up
Delivery time:
Most projects take 5 business days.
Simple parts can be delivered in as little as 1 day.
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Key Benefits of Polyurethane Casting Prototypes

Polyurethane Casting presents numerous significant benefits that establish it as a favored option for rapid prototyping and small-scale production.

Precision in Small Batch Production for Consistent Quality

Polyurethane casting is celebrated for its exceptional dimensional accuracy, making it the preferred choice for producing high-quality, repeatable components in small quantities. This method ensures that prototypes and short-run parts meet rigorous tolerances and aesthetic criteria comparable to those achieved through injection molding.

Urethane Material

Diverse Material Options to Meet Specific Project Requirements

With a broad selection of materials—including heat-resistant, flexible, and optically clear options—polyurethane casting can be customized to fulfill particular project demands. This adaptability is especially advantageous for sectors requiring tailored solutions, such as automotive, medical devices, and consumer products.

Vacuum Casting production

Cost-Effective Solution for Prototyping and Low-Volume Runs

Polyurethane casting offers a budget-friendly alternative to traditional manufacturing methods, especially for prototyping and low-volume production. This approach reduces the need for expensive molds, enabling companies to test and refine their designs without incurring substantial upfront costs.

Vacuum Casting Prototype

Fast Turnaround for Accelerated Development Timelines

Due to its simple tooling and rapid setup, polyurethane casting supports quick production cycles, making it ideal for projects with tight deadlines. This process allows designers to implement swift iterations, hastening the transition from concept to market while maintaining high-quality standards.

Urethane Casting Materials

ABS-Like

Material properties:
Good physical properties, fast curing speed, high precision of finished product size, easy to spray oil, long mold life

2 materials with optional operation time, excellent mechanical properties, easy to color spray paint, long mold life

Color:
White Black Yellow White White

Hardness:
80D 74D 78D 70 50 50

Application:
Shape confirmation and strength confirmation of molded parts, small batch production of products
HIPS (high impact polystyrene)/non-shattering glue
ABS standard parts

Learn more about ABS materials

*For materials not shown here, please contact us directly

Urethane Casting Prototypeing Service FAQs

1. What is urethane casting, and how does it differ from traditional plastic casting?

Urethane casting is a prototyping process where polyurethane resin is used to create parts that resemble injection-molded plastic. Unlike traditional plastic casting, urethane casting is ideal for low-volume production, as it requires a soft silicone mold rather than a hard metal mold. This method is quicker and less expensive, especially for short runs, and offers versatility in replicating both the look and performance of injection-molded parts.

2. What are the typical applications of urethane casting in prototyping?

Urethane casting is widely used in creating functional prototypes, especially for consumer electronics, automotive parts, and medical devices. It’s ideal for validating designs before moving to full-scale production, allowing for thorough testing of form, fit, and function. Additionally, urethane casting is valuable for limited production runs where durability and aesthetics need to closely match final injection-molded products.

3. How does the urethane casting process work?

Urethane casting typically starts with a master model created via CNC machining or 3D printing, which is used to make a silicone mold. Once the mold is prepared, it’s filled with polyurethane resin and left to cure, creating a part identical to the master. This process can be repeated until the mold wears out, usually after 20–25 castings, making it efficient for small-batch production.

4. What materials can be used in urethane casting, and what are their benefits?

Various types of polyurethane resins are available for casting, including rigid, flexible, high-temperature, and clear resins. This range allows manufacturers to select materials based on specific requirements, such as impact resistance, flexibility, or transparency, making urethane casting suitable for diverse applications across industries.

5. How accurate is urethane casting in replicating injection-molded parts?

Urethane casting is highly accurate, often achieving tolerances of ±0.3mm or better. This process can closely mimic the appearance, texture, and mechanical properties of injection-molded parts, making it ideal for realistic prototypes and market-ready products. However, slight variations may occur due to factors like mold shrinkage.

6. What are the advantages of using urethane casting for prototypes?

Key advantages include cost-effectiveness, quick production times, and high customization potential. Urethane casting allows for rapid prototyping with fewer resources compared to traditional methods. Additionally, the process accommodates complex geometries and finishes, which are difficult to achieve with some other prototyping techniques.

7. What is the typical lead time for urethane casting prototypes?

Lead times for urethane casting are generally short, averaging 5–10 days, depending on project complexity and volume. This rapid turnaround is possible because the silicone molds are faster to produce and don’t require the machining involved in metal molds, making urethane casting ideal for projects with tight deadlines.

8. How durable are urethane casting prototypes compared to other methods?

Urethane casting prototypes are durable enough for functional testing, but they don’t typically match the lifespan of injection-molded parts. The durability of each prototype depends on the resin selected. Some urethanes are highly impact-resistant and suitable for limited functional applications, while others are designed more for aesthetic purposes.

9. What is the maximum volume suitable for urethane casting?

Urethane casting is best suited for low to medium-volume production, generally up to 100 parts. This limitation is due to the silicone molds, which degrade with repeated use. For higher volumes, methods like injection molding are more cost-effective and durable.

10. Are there environmental considerations with urethane casting?

Urethane casting does have environmental impacts, as the silicone molds and polyurethane resins are not biodegradable. However, some suppliers offer recyclable options, and the low-volume production aspect reduces material waste compared to high-volume methods. Some companies are also exploring bio-based urethanes to make the process more sustainable.

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