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Rubber-Like Cast Parts

Rubber-Like Cast Parts

Rubber-like cast parts are produced by vacuum casting flexible polyurethane elastomers into silicone molds, delivering parts that closely simulate the tactile and mechanical behavior of TPE, TPU, EPDM, and other thermoset rubbers — without the high tooling investment of injection molding. We support hardnesses from Shore A20 (very soft) to Shore A90 (semi-rigid) for prototyping and low-volume production of seals, gaskets, dampers, and soft-touch parts.
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Description

Mechanical Properties

 

Typical mechanical properties of our flexible cast urethanes (values vary with Shore hardness and resin grade - measured per the relevant ASTM or ISO methods):

Tear strength:

Shore A40 grades typically 15–25 kN/m; Shore A70–80 grades typically 30–45 kN/m (ASTM D624 Die C). Significantly higher than typical SLA flexible resins, supporting functional tests with repeated stretching, twisting, and compression.

Rebound resilience:

typical 40–55% depending on durometer (ISO 4662 / DIN 53512). Parts return promptly to original shape after deformation.

Compression set:

typically ≤20% for medium-hard grades after 22 h at 70 °C (ASTM D395 Method B), supporting sealing and gasket validation.

Service-temperature range:

stable from approximately −40 °C to +80 °C (resin-dependent) without embrittlement or excessive softening.

Numerical values above are typical for representative resin grades. We provide the specific resin data sheet for your project so test conditions, hardness, and relevant standards are explicit.

 

Surface Finish Options

 

We deliver surface finishes close to injection-molded components, supporting production-quality aesthetics on rubber-like cast parts:

  • Texture & grain replication: SPI A1–D3 finishes and standard mold textures (e.g. VDI 3400 series) replicated directly from the master pattern.
  • Soft-touch coatings: premium velvet-like feel for consumer electronics and medical-device interfaces.
  • Color matching: Pantone (PMS) and RAL color systems supported, with typical color deviation ΔE ≤ 1.5 against the reference.
  • Advanced options: optically clear flexible parts, translucent tints, and dual-material overmolding for soft-grip handles.
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Dimensional Accuracy & Geometric Capability

 

The flexibility of silicone molds lets the casting process handle geometries that are difficult for traditional machining:

Specification

Capability

Standard tolerance

±0.3 mm per 100 mm (or ±0.3% of nominal, whichever is larger)

Precision tolerance

±0.15 mm achievable on selected features (geometry- and hardness-dependent)

Minimum feature size

≥0.8 mm

Minimum wall thickness

≥1.2 mm to support full cavity filling

Maximum part size

Up to 600 × 500 × 300 mm (larger on request)

Special capabilities

Deep undercuts, thin-walled sections, integrated metal inserts

 

Lead Times

 

Time-to-market is critical. Our optimized rapid urethane casting workflow supports:
 
 
 

Standard single-mold projects:

5–8 working days from approved master pattern to final castings.

 
 

Complex / multi-cavity molds:

8–12 working days.

 
 

Expedited service:

as fast as 4 working days available for urgent validation needs (subject to capacity).

 
 

The advantage:

compared with the typical 8–14 week lead time for TPE/TPU injection molding tooling, vacuum casting lets you start functional testing months earlier.

 

 

Process Comparison

 

For engineering transparency, here is how urethane casting compares with other common flexible-part processes:

Feature

Urethane Casting

Injection Molding (TPE/TPU)

SLA / DLP Flexible Resin

FDM TPU (3D Print)

Tooling cost

Low (silicone)

High (steel)

None

None

Durability

Strong (industrial use)

Best

Limited (can be brittle / age)

Moderate (delamination risk)

Hardness range

Shore A20–A90, D70–85

Shore A0–D90

Limited options

Limited options

Surface quality

Production grade

Best

Layer lines visible

Rough

Functional test suitability

Highly recommended

Best

Aesthetic only

Basic fit-check

 

Why Choose Us

 

  • Free DFM review: within 24 hours of inquiry, our engineers provide a manufacturability analysis covering wall thickness, undercut design, and gating.
  • Mold life: high-grade addition-cure platinum silicones typically support 20–25 castings per mold while maintaining part-to-part consistency.
  • Quality management: ISO 9001 certified process, with traceability for every seal, gasket, or button.
  • Industry experience: delivered programs in automotive (seals, bushings), medical (catheter prototypes), and consumer electronics (ruggedized cases).
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FAQ

 

Q1: What are rubber-like cast parts?

Rubber-like cast parts are produced by vacuum casting, in which liquid polyurethane elastomers are poured into a silicone mold to create parts that mimic the physical properties of rubbers such as TPE, TPU, or EPDM.

Q2: What Shore hardness range is available?

We support Shore A20 (very soft, similar to a pencil eraser) through Shore A90 (semi-rigid, similar to a skateboard wheel).

Q3: How do rubber-like cast parts compare with injection-molded silicone (LSR)?

Liquid silicone rubber (LSR) offers superior heat resistance and biocompatibility but requires expensive tooling and long lead times. Rubber-like urethane casting provides similar tactile properties and tear resistance with much lower tooling investment, making it a strong choice for prototyping and low-volume production. For final production with high-temperature or strict biocompatibility requirements, LSR injection molding is generally preferred.

Q4: Can rubber-like cast parts be used for functional testing?

Yes. Their tear strength and abrasion resistance make them suitable for automotive vibration testing, drop testing of handheld devices, and fluid-seal validation in prototyping programs.

Q5: What is the minimum order quantity (MOQ)?

There is no MOQ - single-piece orders are accepted. The cost-per-part is most efficient for batches of 5–50 units.

Q6: How are custom colors and textures applied?

The liquid resin is pigmented under vacuum before casting, supporting consistent through-color. Textures are replicated directly from the master pattern with high fidelity.

Q7: Are rubber-like cast parts food-safe or biocompatible?

Specific resin grades are RoHS- and REACH-compliant. If your project requires ISO 10993 biocompatibility or food-contact certification, please specify at quotation so the appropriate medical- or food-grade urethane can be selected.

Q8: What file formats are accepted?

STEP (.stp / .step) and IGES (.igs / .iges) are preferred. For parts with critical fits, please include a 2D PDF drawing with tolerance callouts.

 

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