Urethane Casting Service

Experience the power of precision with KUSLA Prototype’s Urethane Casting services. Fast, high-quality, and customized solutions for diverse industries. Shape your success with us.

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Urethane casting Service

Rigid Urethane resin casting

Urethane resin casting, also known as polyurethane resin casting, is a versatile manufacturing process used to create a wide range of parts and components. It involves the use of liquid urethane resin, which is poured into molds to produce rigid and durable objects with exceptional detail and precision. This process is widely employed in various industries, especially for producing prototypes, low-volume production runs, and intricate parts.

Urethane rubber casting

Urethane rubber casting, or polyurethane rubber casting, is a casting process that utilizes liquid urethane rubber to create flexible and elastomeric parts. Unlike rigid urethane resin casting, this method is ideal for producing components that require flexibility, resilience, and the ability to absorb shock and vibration. Urethane rubber casting is commonly used in applications where soft, pliable materials are essential.

Our Services

Perfect for prototypes and smaller production volumes, urethane casting delivers speedy turnaround, economical tooling, precise results, and a plethora of material choices. With a decade-long expertise in urethane casting, KUSLA Prototype is equipped to manage projects of any magnitude or intricacy, ranging from petite prototypes to extensive production runs.

Utilizing state-of-the-art machinery and technology, we guarantee uniform quality and prompt delivery. Our competitive pricing and bespoke solutions are designed to cater to your unique demands and specifications. Regardless of your industry – be it automotive, medical, aerospace, or others – we stand ready to supply superior products and services.

Rapid Plastic Prototyping

Refine designs and reduce costs with plastic prototyping. Test functionality, assess materials, and gain valuable customer feedback. Utilize 3D printing, injection molding, CNC machining, and…
Rapid Clear Prototyping Sample

Rapid Clear Prototyping

Create transparent prototypes using clear materials like resin, acrylic, and glass. Ideal for optics, lenses, displays, and more. Achieve intricate and irregular shapes with clarity…

KUSLA Urethane Casting Specifications

Lead time As low as 7 days for first part
 Accurateminimum ± 0.3 mm (Vary on dimensions of the part)
Maximum part size914.4 x 914.4 x 1828.8mm (36.0 x 36.0 x 72.0 in)
Minimum feature size0.635mm (0.025 in) for features
1.016mm (0.040 in) wall thickness
 Typical quantities Up to 25 copies per mold
(depending on the mold’s complexity and the casting materials)
 Color & Finishingcustom painting and texture.

Urethane Casting Process

Step 1: Master Pattern Creation

To initiate the urethane casting process, master patterns are crafted from your CAD designs. These master patterns are usually generated through precision methods like CNC machining or 3D printing. The creation of master patterns often occurs at a controlled temperature of 40°C. Once the master patterns are finalized and subjected to quality inspection, we progress to the next stage: the fabrication of silicone molds.

Step 2: Silicone Mold Making  

Urethane casting utilizes casting molds constructed from liquid silicone. The procedure commences by partially filling the casting box with the liquid silicone material. Subsequently, the casting box is heated until the silicone fully cures. Following this, the box is placed in an oven for a curing period of approximately 16 hours. Additional liquid silicone is introduced and similarly heated and cured. Once the silicone solidifies, the mold is delicately opened to extract the master pattern.

Step 3: Cast Production

The final stage encompasses the production of parts. Liquid urethane casting resins are carefully poured into the cavity created by the silicone mold. This results in the creation of highly accurate reproductions of the original master pattern. Additionally, if necessary, the process supports overmolding with two or more materials. Silicone molds are known to maintain their effectiveness for around 20 or more copies of the master pattern, ensuring consistency and reliability throughout the production process.

Urethane Casting Material

Polyurethane stands out as a highly utilized thermoset material renowned for its exceptional strength, durability, resistance to abrasion, and remarkable versatility. Various formulations of urethanes possess the ability to replicate the properties of numerous widely used thermoplastics. To streamline decision-making and ensure optimal performance for your projects, we classify our urethane materials into distinct categories. The following list provides an overview of these material categories and includes technical examples to guide your selection of polyurethanes.

Type of MaterialCommentColorHardnessMaterial reference
urethane casting resin(Rigid)ABS-LikeABS-Like is a general-purpose polyurethane plastic that simulates ABS thermoplastic. This material is a great choice for most product enclosures.
All colors
Shore D 76-80BJB TC-852
Acrylic-LikeAcrylic-Like is a stiff, transparent polyurethane plastic that simulates acrylic (PMMA). This material is great for see-through applications such as light pipes.Transparentshore D 80Polytek Poly-Optic® 14 Series
Polycarbonate-LikeA stiff, USP Class VI, high-performance urethane with high impact strength and a HDT of 190°F (88°C).Transparentshore D 82-86BJB TC-854
urethane casting Rubber
Rubber-Like Polyurethanea polyurethane plastic that simulates all kinds of rubber-like materials such as TPE, TPU, and silicone rubber. This material is great for wearables, gaskets, and overmolds
All colors
20-95Shore ABJB F-170
Clear Rubber-Like PolyurethaneA colorless Shore A elastomer with a high elongation to break. Matte finish will give a frosted appearance, and higher gloss will increase its transparency.Transparent40-95 Shore ABJB WC-565

Surface Finish for Urethane Casted Parts

Kusla Prototype offers a diverse range of surface finishes that allow us to craft distinctive surface layers for your Urethane-casted components. These finishes are strategically designed to align with the desired appearance, hardness, and chemical resistance specifications of your products. Our selection of surface finishes caters to various material choices and part applications, ensuring that we provide you with tailored solutions.

Surface Finishing

Enhance product durability and visual appeal with our expert surface finishing services. From polishing to coating, we offer a wide range of specialty options to meet your needs for rapid…
Read More Surface Finishing

Benefits of Urethane casting prototypes

Reduced tooling and part costs

urethane casting requires minimal tooling and investment compared to other methods such as injection molding or additive manufacturing. Silicone molds are relatively cheap and easy to make, and also offer lower part costs especially as the order volume increases. Because Urethane casting can produce multiple parts in one shot, avoiding the need for additional cycles.

Impressive speed and quality

 Silicone molds can be ready in as little as 24 hours. Up to 50 functional cast urethane parts can be produced in 10 days when you choose urethane casting.  Urethane casting can produce parts with excellent surface finish, accuracy, and detail. The parts are also durable and resistant to heat, chemicals, abrasion, and impact. Urethane casting can replicate the look and feel of production-like parts, making it ideal for prototyping and testing purposes.

Design flexibility

urethane casting allows you to create parts with complex geometries and features that would be difficult or impossible to achieve with other methods. And A wide materials choices range from soft and flexible to rigid and impact-resistant, as well as colored and clear.

Why Choose KUSLA Urethane Casting Services?

Our Urethane casting technicians to control all operational parameters: mixing, de-gassing, stirring, preheating, casting, and de-molding, allowing for near-perfect copies of the master pattern to be created. 

Urethane Casting plastic parts 
Lead time Up to 50 copies can be produced in 7 to 10 days,
Lifetime of the silicone mold Typical quantities up to 20-25 copies per mold. 
Cost 20% Lower than Market

Other Capabilities

Rapid Tooling

Achieve success with KUSLA Prototype’s high-quality and cost-effective rapid tooling services. Fast turnaround, advanced technology, and skilled engineers for your…
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FAQs About Urethane Casting

Urethane casting, also known as polyurethane casting or vacuum casting, is a manufacturing process used to create custom, low-volume manufacturing parts and rapid prototypes with the mechanical properties of thermosetting polyurethane materials. This process is often chosen when traditional injection molding is not cost-effective or practical due to factors like small production volumes, complex part geometries, or the need for rapid prototyping.

Urethane casting can be used to create rigid or rubber-like parts, making it ideal for a variety of applications.

  • Medical Devices: Urethane casting is widely used in the medical industry to create various medical devices and equipment. For instance, it can be used to make realistic anatomical models for surgical planning and medical training.
  • Automotive Parts: In the automotive industry, urethane casting is employed to create car components such as bumpers, dashboard panels, and trim parts. It allows for the production of parts with complex geometries and high durability.
  • Consumer Products: Many consumer products, including toys, household appliances, and electronics, use parts made from urethane casting. For example, urethane casting can produce over 10,000 units of a particular toy part within a month, catering to the high demand in peak seasons.
  • Industrial Equipment: Urethane casting is also used in the production of various industrial machines and equipment. It can produce up to 500 units of machine parts, like gears and casings, within a week, depending on the complexity and size.
  • Prototype Development: Urethane casting is extensively used for creating prototypes. For instance, a startup can utilize it to produce up to 100 prototypes of a new product within a few weeks for testing before mass production.
  • Aerospace Components: The aerospace industry uses urethane casting for parts that require high strength and durability, such as internal components and cabin fixtures. It can produce several hundred units of a specific part within a month, depending on the component’s complexity.

Please note that the actual data can vary based on different factors such as the complexity of the parts, the size of the parts, and the specific requirements of the project.

Urethane casting offers a cost-effective solution with fast turnaround, low tooling cost, and a high degree of accuracy.

Our urethane casting services cater to a broad spectrum of industries, including automotive, medical, aerospace, and more.

Yes, with our decade-long experience, we are equipped to manage urethane casting projects of any size or complexity.

We offer a wide range of material options for urethane casting, including different types of plastics and flexible urethane resins.