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Thursday, May 1, 2025
TECHNOLOGIESTRADITIONAL MANUFACTURINGUrethane Casting

Cast Urethanes

CAST URETHANE

Produce high-quality prototypes and low-volume production parts

Urethane castings closely simulate injection molded parts. This gives our clients a fast low-cost process for producing prototypes and low-volume production parts without the high cost of metal tooling. Urethane casting involves creating a master model, typically using 3D printing, which is then used to make a silicone mold. Liquid urethane is poured into the mold and cured to form the final part.

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Cast Urethane

Why Choose Urethane Casting?

Urethane casting remains popular due to its cost-effectiveness for small-scale production, rapid turnaround times, and excellent surface finish quality.

It serves as a bridge between prototyping and full-scale production, allowing for design validation and functional testing without the high costs associated with traditional manufacturing methods like injection molding.

Cast Urethane Projects

Prototyping: Create functional prototypes with high precision and detail.

Low-Volume Production: Ideal for producing small batches of parts quickly and economically.

Design Flexibility: Supports complex geometries and a wide range of material properties.

Customization: Offers options for color, texture, and finish customization.

Applications

Rapid Prototyping

When you need a prototype, VCM is a good solution for quickly producing highly detailed parts.


Short Run Production

Get the parts you need faster, minimizing costs without extra post-production processes.


Manufacturing Fixtures

MJF is cost-effective, durable, and precise, making it an excellent option for manufacturing fixtures and jigs.

Materials


    Rigid Materials
    TC-852 TC-854 TC-890 TC-895 TC-885 FR WC-783
    General
Purpose		 High Impact RoHS
compliant		 Heat
 Resistant		 Fire
Retardant		 Water
Clear
PHYSICAL PROPERTIES: Off White Transparent Yellow White Black Off White Clear
Hardness , Shore D ASTM D-2240:  78 (+/-) 2 84 (+/-) 2 80 (+/-) 2 84 (+/-) 2 78 (+/-) 2 82 (+/-) 2
Tensile Strength, (psi) ASTM D-638:  7,000 10,060 7,600 10,300 5,950 6,650
Tensile Modulus, (psi) ASTM D-638:  240,000 330,000 240,000 293,000 224,000 260,000
Flexural Strength, (psi) ASTM D-790:  10,500 13,700 10,000 12,700 9,600 11,000
Flexural Modulus, (psi) ASTM D-790:  270,000 360,000 250,000 317,000 265,000 320,000
Izod Impact, (ft.-lb./in.) ASTM D-256:  0.70 1.14 0.70 0.88 0.57 1.00
Elongation, (%) ASTM D-638:  12.0 10.5 10.0 9.1 20.0 65.0
Density, (g/cc) ASTM D-792:  1.15 1.20 1.14 1.12 1.26 1.05
  Cu. In. / Lb.:  25.2 24.5 25.0 24.0 22.6 26.4
Heat Deflection Temperature            
  HDT - ASTM D-648
 @ 66psi: 		 220F (+/-) 5F 190F (+/-) 5F 195F (+/-) 5F 340F (+/-) 5F 190F (+/-) 5F 158F (70C)
  HDT - ASTM D-648
 @ 264psi: 		 200F (+/-) 5F 170F (+/-) 5F 177F (+/-) 5F 218F (+/-) 5F 173F (+/-) 5F  
Coefficient of Thermal Expansion, (in/in/F) ASTM E831-06:        0.0000731   0.0000900
Compressive Strength, (psi) ASTM D-695:            8,350
Compressivel Modulus, (psi) ASTM D-695:            350,000


    Flexible Materials - F Series  (see additional materials below)
    F-15 F-25 F-32 F-42 F-50 F-60
    General
Purpose		 General
Purpose		 General
Purpose		 General
Purpose		 General
Purpose		 General
 Purpose
PHYSICAL PROPERTIES: Pale Yellow Pale Yellow Pale Yellow Pale Yellow Pale Yellow Pale Yellow
Hardness , Shore A ASTM D-2240:  15 (+/-) 5 25 (+/-) 5 32 (+/-) 5 42 (+/-) 5 55 (+/-) 5 60 (+/-) 5
Tensile Strength, (psi) ASTM D-412:  235 345 675 730 845 685
Tensile Modulus, (psi) ASTM D-412:             
   @100% Straine:          150 312
   @200% Straine:          275 497
   @300% Straine:          390 623
Elongation, (%) ASTM D-638:  600 1,100 950 660 425 300
Tear Strength (pli) ASTM D624-00e1 24 45 85 76 95 57
Density, (g/cc) ASTM D-792:  1.02 1.03 1.06 1.09 1.07 1.06
  Cu. In. / Lb.:  27.3 26.9 27.1 26.0 26.1 26.0
               
    Flexible Materials - F Series  (see additional materials below
    F-62 FR F-64 F-70 F-82 F-85 F-90
    Flame
Retardant		 General
Purpose		 General
Purpose		 RoHS
compliant		 General
Purpose		 General
Purpose
PHYSICAL PROPERTIES: Pale Yellow Translucent
Neutral		 Translucent
Yellow		 Pale
Yellow		 Buff Opaque Tan/Opaque
Hardness , Shore A ASTM D-2240:  60 (+/-) 5 65 (+/-) 5 70 (+/-) 5 80 (+/-) 5 85 (+/-) 5 90 (+/-) 5
Tensile Strength, (psi) ASTM D-412:  625 1,200 940 2,100 2,500 3,000
Tensile Modulus, (psi) ASTM D-412:        364   3,300
   @100% Straine:      430      
   @200% Straine:      660      
   @300% Straine:      900      
Elongation, (%) ASTM D-638:  310 515 315 385 275 440
Tear Strength (pli) ASTM D624-00e1 60 125 87 178 180 300
Density, (g/cc) ASTM D-792:  1.09 1.07 1.11 1.09 1.08 1.08
  Cu. In. / Lb.:    26.2 25.8 25.9 25.7 25.6
               
    Flexible Materials - STSeries
    ST-1060 ST-1075 ST-1085 ST-1087 ST-3040 ST-3050
    High Tear
Strength		 High Tear
Strength		 High Tear
Strength		 Flame
Retardant		 General
Purpose		 General
Purpose
PHYSICAL PROPERTIES::   Amber Clear Amber Clear   Pale Yellow Amber Clear
Hardness , Shore A ASTM D-2240:  60 (+/-) 5 75 (+/-) 5 85 (+/-) 5 83 (+/-) 5 40 (+/-) 5 50 (+/-) 5
Tensile Strength, (psi) ASTM D-412:  900 1,600 2,125 1,500 765 1,200
Tensile Modulus, (psi) ASTM D-412:             
   @100% Straine:  300 650 761   100  
   @200% Straine:  445 820 996   180  
   @300% Straine:  560 980 1,219   225  
Elongation, (%) ASTM D-638:  590 550 600 300 1,500 1,400
Tear Strength (pli) ASTM D624-00e1 120 190 255 160 120 185
Density, (g/cc) ASTM D-792:  1.05 1.10 1.10 1.08 1.07 1.07
  Cu. In. / Lb.:  26.3 25.6 25.7 26.0 26.1 26.2

CAST URETHANE FAQs

How does urethane casting compare to injection molding for low-volume production?
Urethane casting offers significant advantages for quantities under 100 pieces:
  • No expensive hard tooling required (saving $10,000-50,000 in mold costs)
  • Faster turnaround times (48-72 hours vs. 4-8 weeks)
  • Design changes can be implemented quickly without new tooling
  • Comparable material properties and surface finish
  • Lower minimum order quantities (as low as 1 piece)
Can urethane cast parts include special features like threaded inserts or multiple materials?
Yes, our advanced casting process accommodates various special features:
  • Metal threaded inserts and bushings
  • Overmolded sections with different durometers
  • Embedded electronics or sensors
  • Clear windows or sections
  • Color matching to Pantone specifications
  • Custom textures and surface finishes
These features can be incorporated without additional tooling costs, making complex assemblies more cost-effective in low volumes.
Have more Questions?

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