Urethane casting cost is a key factor for a plastic prototype project. It is a low-cost solution for plastic prototyping when requires small quantities. However, How much does urethane casting cost? What factors affect the Urethane casting cost? How it is calculated? In this article, as a urethane casting service provider, KUSLA will answer these questions for you.
What is Urethane casting?
Urethane casting utilizes liquid polyurethane resin that is poured into the silicone mold and then creates plastic or rubber parts in Vacuum status. It is a cost-effective method for making a small series of parts around 10 to 100 units.
Urethane casting Processes
Before you understand the cost of urethane casting, it is need to understand the process of Urethane casting, each process will contribute to the final cost of Urethane parts.
Master Pattern Creation
The first step is to create the master pattern part by CNC machining or 3D printing. CNC machining is commonly used to create parts with high smooth surface such as clear parts. 3D printing can be used for those parts with complex structures.
Making silicone mold
Surround the master pattern with a mold frame, then pour the liquid silicone material into it. After solidification, the silicone mold is formed. Once is mold is cured, take out the mold and Cut the mold along the product parting line, and then remove the master pattern and leave the mold cavity empty.
Casting urethane parts
Pour the liquid Urethane material into the silicone mold in a vacuum environment, then heat and cure the urethane part at a high temperature to obtain a replica mold cavity part.
Post-processing
Once the urethane part is cured and taken out of the silicone mold, it needs post-processing such as Removing burrs and gates, repairing pores, Polishing, and assembling tests.
Surface finishing
the final step is to make surface finishes on the urethane parts according to the requirements such as spray painting, screen printing, laser engraving, etc.
Factors that affect the cost of urethane casting
Master Pattern
The cost of a master pattern is the same as manufacturing a one-off prototype by CNC machining or 3D printing. 3D printing is a low-cost solution for master pattern making, So if you need to lower the total cost of urethane casting parts, choose 3D printing as much as you can to make the master pattern.
Silicone mold
Typically, the silicone mold used for urethane casting costs between $50 and $500, but the cost can vary significantly depending on its nature, size, complexity, and manufacturing location. The silicone mold cost can be amortized to the unit cost, which means the more prototypes you make, the lower the unit cost you can get.
Urethane Casting material
Commonly, The urethane casting material cost ranges from $0.5 to $1.5. Urethane Casting part Materials are wide and varied with different urethane materials representing different thermoplastics like ABS, nylon, or PC-like materials. There are several different brands and the prices are quite wide.
Surface finishes
Surface finish is another factor to affects the urethane casting cost this is because surface finish costs vary according to different techniques such as spray painting, screen printing, and laser engraving which also contribute to the final urethane part cost.
How to Calculate Urethane Cost?
The total urethane casting cost is “master pattern cost + silicone mold costs +unit urethane part cost*quantities“. The silicone mold is usually only available for 25 copies, so if the quantity is over 25, another silicone mold is needed. And unit urethane part is ”urethane material cost per gram*part weight + surface finish cost”.
Urethane casting cost overview
Urethane casting usually works for a production volume of 10 to 100 units. On average, the urethane casting for small parts is around $100 – $1000 in total, and the per-unit price ranges from $10 to $100. let us take an example with 10 – 100 parts run to explain each item:
assume plastic part information:
- Plastic part size: 100mm*100mm*10mm
- Thickness: 2mm
- weight: 20g
- material: ABS-like plastic
The Urethane casting cost is calculated below:
- Number of parts: 10 Units
- Mater pattern cost by CNC machining: $100
- Unit material cost: $5
- silicone mold cost: $100
- Unit surface finishing cost: $0.5
- Logistic cost per part: $0.5
- total volume cost: $100+$100+($5+$0.5+$0.5)*10=$260
- Final cost per Part: $26
Urethane casting cost VS injection molding cost
Urethane casting and injection molding can be both used for small-volume productions. urethane casting uses silicone mold which is less expensive than the toling used for injection molding. However, injection molding can create parts in large volumes above 1,000 parts. urethane casting need takes a very long time and will need many silicone molds to create parts with this quantity. So when the quantity is small, Urethane casting cost lower than injection molding. when the quantity is big, injection molding cost will be more cost-effective.
Tips for Reducing the cost of urethane casting
Here are some tips according to our experiences of many projects:
- Use a carton box as a mold frame
- Use proper and low-cost urethane materials
- Simplify the product geometry
- design constant wall thickness
- Order quantities according to the capacity of one silicone mold
- Reduce Waste during casting and mold design
Conclusion
This article explains how to calculate the urethane casting cost according to all the factors, However, to get an accurate budget or price for your urethane casting project, you need to work with a professional manufacturer of urethane casting service. At KUSLA, we’re experienced with urethane casting and Our expert team can provide technical assistance, ensuring your designs are optimized for the casting process.
FAQ
Is urethane casting expensive?
It depends. Urethane casting is much less expensive than other rapid prototyping methods such as CNC machining and injection molding when you want production parts in small batches of 10 to 100 pieces.
What is the lead time for urethane casting?
Urethane casting parts can be ready in as few as one to two weeks, no matter the part size.
