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Polyurethane Cast Prototypes

Polyurethane Cast Prototypes

Polyurethane cast prototypes — produced by vacuum casting into silicone molds — combine production-relevant material properties with rapid turnaround and low tooling cost. This page focuses on material grades, mechanical properties, and selection guidance for engineers choosing the right polyurethane resin for their project.
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Description

Material Performance & Consistency

 

Core advantages:

  • Rapid delivery: typical projects completed in 5–8 working days, from master pattern to final part
  • Wide hardness range: Shore A20 (rubber-like) to Shore D85 (rigid plastic)
  • Low-volume economy: ideal for batches of 1–500 units, with no hard tooling investment
  • Material simulation: resins engineered to approximate the mechanical behavior of common production plastics
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Manufacturing Capabilities

 

Standardized quality control supports consistent results across every urethane casting project:

Maximum part size: up to 600 × 500 × 300 mm (oversized parts can be cast in sections and bonded).

Standard tolerance: ±0.3 mm per 100 mm (or ±0.3% of nominal, whichever larger). Tighter tolerances of ±0.15 mm achievable on selected features after DFM review.

Minimum wall thickness: 1.0 mm recommended for consistent resin flow.

Surface finish options: matte, high-gloss mirror polish, textured (VDI 3400), painted, plated, or silk-screened.

Color matching: Pantone (PMS) and RAL color systems supported.

 

Polyurethane Material Options

 

Below are typical specifications for representative urethane casting resins. Exact properties vary by resin grade and supplier - we provide the specific data sheet for your selected material.

Resin Family

Simulates

Shore Hardness

Tensile Strength (MPa)

Elongation at Break

HDT (°C)

Color

ABS-equivalent rigid

ABS

Shore D80–85

55–65

10–20%

~80–90 (@1.82 MPa)

Pigmentable

PP/HDPE-equivalent

PP / HDPE

Shore D60–75

30–45

20–60%

~70–80 (@1.82 MPa)

Pigmentable

Optically clear

PMMA / PC (visually)

Shore D80–85

50–60

8–15%

~75–85 (@1.82 MPa)

Optically clear / tinted

Flexible elastomer

TPE / TPU / soft rubber

Shore A20–A90

1–25 (hardness-dependent)

150–500%

n/a (durometer-defined)

Pigmentable

High-temperature rigid

Heat-resistant ABS / engineering plastic

Shore D80–85

55–65

8–15%

~120 (@0.45 MPa)

Black / gray

Tensile and elongation values for flexible elastomers vary widely with durometer - softer grades (A20–A40) produce low tensile strength and high elongation, while harder grades (A80–A90) produce higher tensile strength and lower elongation. HDT values are reported with the load condition specified, per ISO 75 / ASTM D648; @0.45 MPa values are higher than @1.82 MPa for the same resin.

 

Process Comparison

 

Choosing the right process is essential for budget and timeline. Below is an objective comparison of polyurethane casting against alternative methods:

Feature

Polyurethane Casting

Injection Molding

SLA 3D Printing

Tooling cost

Low (silicone mold)

High (steel / aluminum)

None

Lead time

5–10 working days

8–14 weeks

1–3 days

Surface finish

Excellent (replicates master)

Best

Layer lines visible without finishing

Functional testing

Strong (production-relevant)

Best

Limited (some grades brittle)

Ideal volume

10–500 units

1,000+ units

1–5 units

 

Custom Polyurethane Casting Services

 

We support bespoke urethane prototypes for complex engineering requirements:

Custom color & texture:

resin pigmenting before casting, plus custom mold textures matched to your final product.

01

Custom hardness formulations:

 component mix ratios adjusted to achieve specific tactile properties or spring rates.

02

Inserts:

integration of threaded inserts, conductive contacts, or magnets directly into the cast part.

03

Clear & translucent parts:

PMMA-like clarity for lenses, fluid manifolds, and light pipes.

04

Two-material assemblies:

overmolding different durometer resins to simulate dual-material injection molding (see Overmolded Cast Prototypes).

05

 

FAQ

 

Q1: What are polyurethane cast prototypes?

Polyurethane cast prototypes (also called vacuum casting) use a silicone mold taken from a 3D-printed or CNC-machined master pattern. It is a rapid manufacturing process for creating high-performance plastic or rubber-like parts without the cost of hard tooling.

Q2: How accurate are polyurethane cast prototypes compared with injection-molded parts?

Cast parts typically achieve tolerances of ±0.3 mm per 100 mm. Injection molding generally reaches ±0.05 mm. Vacuum casting accuracy is sufficient for the majority of functional tests, assembly fit checks, and marketing samples.

Q3: What is the minimum order quantity (MOQ)?

There is no MOQ - single-piece orders are supported. Cost-per-part is most efficient for batches of 10–50 units due to the fixed cost of the silicone mold.

Q4: How long does the polyurethane casting process take?

After CAD approval, the master pattern and silicone mold are typically completed within 3 working days. Total production and finishing usually takes 5–8 working days.

Q5: Can polyurethane cast prototypes be used for functional testing?

Yes. Our resins are formulated to approximate the mechanical properties (tensile strength, impact resistance, heat deflection) of production plastics, supporting drop tests, ergonomic validation, and assembly checks.

Q6: Which materials can polyurethane casting simulate?

Common simulations include ABS, PP, HDPE, PC, PMMA, TPE / TPU / soft rubber, and heat-resistant engineering plastics. The match is close in look-and-feel and short-term mechanical behavior; for long-term continuous-service performance the production resin should still be evaluated.

Q7: How do I choose the right Shore hardness?

Shore A is for flexible materials (A40 ≈ pencil eraser, A90 ≈ skateboard wheel). Shore D is for rigid materials (D80 ≈ hard hat). Our engineers recommend a grade based on application duty and feel.

Q8: Are your polyurethane materials food-safe or biocompatible?

Specific resin grades are RoHS- and REACH-compliant. If your project requires food-contact or ISO 10993 biocompatible materials, please specify during the quoting process.

Q9: What file formats do you need?

All major 3D CAD formats are accepted: STEP, IGES, and STL. 2D drawings are helpful for defining critical-fit tolerances.

 

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