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.
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
Rapid Clear Prototyping
KUSLA Urethane Casting Specifications
| Lead time | As low as 7 days for first part |
|---|---|
| Accurate | minimum ± 0.3 mm (Vary on dimensions of the part) |
| Maximum part size | 914.4 x 914.4 x 1828.8mm (36.0 x 36.0 x 72.0 in) |
| Minimum feature size | 0.635mm (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 & Finishing | custom 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 Material | Comment | Color | Hardness | Material reference | |
| urethane casting resin(Rigid) | ABS-Like | ABS-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 76-80 | BJB TC-852 |
| Acrylic-Like | Acrylic-Like is a stiff, transparent polyurethane plastic that simulates acrylic (PMMA). This material is great for see-through applications such as light pipes. | Transparent | shore D 80 | Polytek Poly-Optic® 14 Series | |
| Polycarbonate-Like | A stiff, USP Class VI, high-performance urethane with high impact strength and a HDT of 190°F (88°C). | Transparent | shore D 82-86 | BJB TC-854 | |
| urethane casting Rubber (Elastomers) | Rubber-Like Polyurethane | a 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 A | BJB F-170 |
| Clear Rubber-Like Polyurethane | A colorless Shore A elastomer with a high elongation to break. Matte finish will give a frosted appearance, and higher gloss will increase its transparency. | Transparent | 40-95 Shore A | BJB 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
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 | |
| Accuracy | ±0.1mm/100mm, |
| 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
CNC Aluminum Machining
3D Printing Prototype
CNC Machining
Rapid Tooling
Aluminum Die Casting
Surface Finishing
Aluminum Extrusion
Sheet Metal Fabrication
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