What is Urethane & How to use it?

The urethane casting process is widely used in various industries, Due to the outstanding properties of Urethane, the urethane parts can be used in different applications by engineers. However, Do you know What urethane is? Today, in this article, KUSLA, a urethane casting service provider, will explain everything about urethane and how to use it for different applications.

What is Urethane?

Urethane is an organic compound material, Depending on the production process and different degrees of cross-linking, urethane can exhibit the properties of plastic or rubber. It is commonly used in solid foam or liquid form and can be processed to make plastics, rubber, foam, fibers, coatings, adhesives, and functional polymers.

What is the difference between Polyurethane and urethane?

The answer is that Urethane and polyurethane are the same thing. Polyurethane is a polymer consisting of repeating units chemically linked in a particular pattern. Some of the repeating units are urethane groups. Polyurethane means that it contains multiple urethane groups.

Properties of Urethane

The chemical formula for urethane is C3H7NO2. Here we explain some of the main properties that make urethane a good choice for many industries:

Hardness 

The hardness of urethane is measured on the Shore scale which can range from 20 shore A (as soft as rubber) up to 85D (as hard as typical thermoplastics like Polycarbonate). This wide range of hardness allows urethane to be used in applications from soft rubber to hard plastic. below is a hardness scale chart for your better understanding.

Abrasion resistance

Urethane is well known for its exceptional resistance to abrasive and erosive damage which makes it a good choice where severe wear is a problem. for example, Urethane rubber has 10 times higher abrasion resistance than other elastomers. 

Chemical resistance 

Another important property of Urethane is its chemical resistance. it is resistant to many chemicals, including oils, solvents, fuels, and aggressive chemicals. This makes it widely used in industries that require Chemical resistance and can withstand harsh environments.

Compression set

Urethane has high load-bearing capabilities, Products made of urethane can handle more stress without failing than most other materials, making it ideal in applications requiring compressive resistance such as fall-arrest dampers in elevators and railway line stops.

Tear Strength 

Urethanes have excellent tear strength and can resist tears or punctures that occur when removing Urethane parts from mold due to the pulling force when trying to break the tension between the mold and the cast part. Higher tear strength keeps the mold from tearing for easier part removal and a longer-lasting mold. this makes the Urethane casting service is a cheap solution for making multiple parts by the silicone mold.

Tensile Strength

Tensile strength is the maximum stress that a material can withstand while being stretched or pulled before failing. While urethane elastomer is not commonly used in tensile applications due to its high elongation and creep, it still offers good tensile strength. 

Types of Urethane

There are two main types of Urethane: Polyester Urethane and Polyether Urethane, Within the polyester and polyether groupings, Commonly there are TDI(toluene Diisocyanate) Polyester, MDI(methylene Diisocyanate) Polyester, MDI polyether, TDI polyether, NDI(Naphthylene Diisocyanate) Polyester, and TDI Polycaprolactone.

• TDI Polyester: Excellent abrasion resistance and chemical resistance, commonly with hardness ranging from 70A to 70D.
• MDI Polyester: FDA grade for use with food, commonly with hardness ranging from 85A to 95A
• TDI PTMEG Polyether: Good low-temperature flexibility and is resistant to microbial growth, commonly with hardness ranging from 90A to 70D.
• MDI PTMEG Polyether: outstanding dynamic properties and is highly resilient, commonly with hardness ranging from 60A to 95A.
• NDI Polyester: advanced urethane type offers some of the best load-bearing capacity, commonly with hardness ranging from 65A to 60D.
• TDI Polycaprolactone: good dynamic properties and better hydrolysis resistance, Commonly with hardness ranging from 60A to 55D

Advantage of Urethane

Durability

Due to its good chemical resistance and Abrasive resistance, Urethane parts are durable when used in harsh environments and heavy load conditions. This advantage makes it ideal for applications like automotive parts, flooring, and heavy machinery.

Flexibility

urethane elastomers can be bent, stretched, and returned to its original shape without losing its integrity. this advantage makes it a perfect choice for products that require both elasticity and strength, such as watch straps.

Cost-effective

Urethane is a relatively low-cost material compared to other plastic and rubber materials. This means urethane parts can be produced in large quantities at low cost.

Customizable

Urethane can be customized easily according to the material property needs of different applications. this is because urethane can be manufactured in a wide range of colors, hardness levels, and forms with additives. and also you can mix Ingredients to get the property you need.

Manufacturing Processes using Urethane

There are different ways you can create your product in the urethane manufacturing process. You can use open-cast molding, spin casting, extrusion, injection molding, or compression molding,

Open cast molding

Open-cast molding is widely used for urethane casting parts in the market, it starts with liquid polyurethane but is poured into an open silicone mold, then Heat the mold and urethane liquid to cure and finalize the product.

Spin casting

Spin casting involves using a spinning mold to cure liquid polyurethane to a solid part. while the mold rotates, the inside air is removed.

Extrusion

Urethanes can be melted and formed into different shapes through the extrusion process. it is commonly used for making tubes and films in urethane materials.

Injection molding

liquid urethane can be injected into a mold by low-pressure injection molding and then form the final product. The mold has openings that allow air to slowly escape.

Compression molding

Compression molding uses heat and pressure to cure the liquid urethane material which is poured into a compression mold.

What is Urethane Used for?

Urethane is a highly versatile compound with a wide range of uses. Urethane is most commonly used in a liquid form as a coating, adhesive, sealant, pesticide, fungicide, and more. Here we looking its use in more detail:

• Coating: urethane can provide a protective layer as a coating that increases the durability and appearance of surfaces. it helps the parts against scratches, dents, and weather damage.
• Adhesive: Urethane is a good material that makes adhesives with strong bonding properties. Urethane adhesives are used in various applications to bond materials like wood, metal, and plastic.
• Sealant: Urethane is resistant to water, oil, and oxidation which Is good for for making sealants that provide a durable, flexible seal.
• Pesticides and Fungicides: Urethane compounds are used as pesticides and fungicides which could help protect crops from pests and diseases.
• Plastics: Urethane can be used as plastic by the proper process such as tubes and cast molding parts because It offers flexibility, durability, and resistance to wear and tear.
• Textiles: Urethane can be used to make synthetic fibers and coatings in the textile industry. These fabrics are lightweight, breathable, and easy to maintain.
• Dyes: Iurethane is used in the dye industry to help the dye to the fabric, ensuring that the colors do not fade easily and are long-lasting.
• Solvent: Urethane can act as a solvent in various chemical processes. It helps dissolve other substances, making it easier to mix and apply different chemical formulations.
• Insulation: urethane can be used as insulation which helps reduce energy consumption by keeping interiors warm in winter and cool in summer. it is a popular choice for insulating homes and buildings.

Industry Applications of Urethane Materials

Automotive industry

Urethane is widely used in the automotive industry such as foam and plastic in car components such as seats, car bodies, car lights, bumpers, spoilers, doors, and windows.

Furniture

urethane is commonly used in the furniture industry, especially for cushioning in sofas, chairs, and mattresses. Flexible urethane foam provides comfort and support while being durable and lightweight.

Packaging

urethane foam is used in the packaging industry to protect delicate items during shipping. Its shock-absorbing properties and custom moldability make it ideal for packaging fragile goods like electronics, and medical devices.

Electronics

urethane is widely used in the electrical and electronics industries to encapsulate, seal, and insulate fragile components such as printed circuit boards, underwater cables, and microelectronic devices.

Appliances

Urethane plays a key role in many household appliances. Its primary use is in the form of rigid foams, which provide thermal insulation for refrigerators and freezers.

Buildings and Construction

Modern homes demand materials that are strong yet lightweight, high-performing yet easy to install, and durable yet versatile. Urethane meets these needs while also helping conserve natural resources and reduce energy consumption, which benefits the environment.

Apparel

With advancements in polyurethane manufacturing techniques, a wide range of urethane-based clothing can now be made. This includes synthetic leather and man-made skins used in garments, sportswear, and various accessories.

Flooring

urethane is also a key material in flooring solutions. It is used as a protective coating for wood, vinyl, and concrete floors, offering durability, abrasion resistance, and ease of maintenance. urethane-based floors are particularly popular in high-traffic areas like schools, hospitals, and commercial spaces.

Top 9 Urethane Material Manufacturers

Here we list the top Top 9 Urethane Material Manufacturers websites so that you will find the proper grades urethane you need for your projects. Check below:

1. Filoform
2. Dow Corporate
3. Polycast Industries, Inc.
4. Smooth-On, Inc.
5. AGC Inc.
6. Asia Industry Co.,Ltd.
7. DIC CORPORATION
8. Pelnox
9. Arakawa Chemical Industries,Ltd.

Which Urethane is Best for My Application?

Selecting the right type of urethane can be a complex task, as it requires a thorough understanding of the various grades, each with its own advantages and disadvantages. At KUSLA, we have extensive experience in identifying the ideal urethane grade for specific applications and can assist you in finding the perfect match for your project. Reach out to a KUSLA expert or request an instant quote for urethane casting today.

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