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The Urethane casting process relies on the use of silicone rubber to make the tools that are then injected with thermoset urethanes to create end-use parts. Urethane casting materials options are wide-ranging in mechanical properties, colors and transparencies and can be suitable replacements for many common production engineering plastics.
In an industry like automotive where there are layers of testing requiring builds and subsequent changes, the flexibility afforded from urethane casting can mean saving hundreds of thousands of dollars by avoiding expensive tool changes or even tool scrapping. With millions of dollars of tooling on the line, urethane casting is used in nearly every beta build in automotive.
Larger plastic parts such as interior paneling or ducting are ideal because of the very large and expensive production tools needed.
Fathom's urethane casting capabilities are some of the best in the industry, using a wide range of proven resins with the ability to create some of the largest parts needed.
With equipment able to handle parts in excess of 1,000 mm, Fathom can support any beta build requirements for urethane cast parts.
Color matching, material certification, and finishing techniques like texturing, polishing, plating are all options that can be used to make anything from basic functional parts to fully cosmetic production-ready parts.
Urethane casting is an essential tool for creating production ready parts at lower volumes while minimizing large tooling investments. Whether it is a low volume manufacturing run for a beta build, initial samples for a marketing activity or even a bridge to production while steel tools are being cut, urethane casting is an extremely valuable manufacturing process for quantities typically anywhere from 10 to 1,000 parts.
Urethane casting is a manufacturing process for making prototype and low-volume parts by using a silicone mold to form urethane parts. The parts are made out of materials that are plastic-like or rubber-like.
Denny Scher | ICOMold
Urethane casting is a manufacturing process for making prototype and low-volume parts by using a silicone mold to form urethane parts. The parts are made out of materials that are plastic-like or rubber-like.
For more information, please visit Urethane Casting Services.
The process can be ideal for quantities up to about 25 parts, and it has several advantages over other plastic manufacturing processes like injection molding and additive manufacturing (3D printing): It is fast, inexpensive, and produces high-quality parts.
The urethane casting process is very fast because the silicone molds used to make parts via this process are created very quickly, especially compared to the hard tooling used in injection molding. It is ideal for low-volume production, when quantities do not justify investment in injection mold tooling.
If the plan is to injection mold a large quantity of parts, but some are needed immediately, then urethane casting is a fast method to obtain first-run parts made before the production tooling is ready.
It's excellent for testing product design, for one-off products, or for testing market or consumer responses to a new product. With such a quick turnaround time, urethane casted parts can bring a project to its next level for end-user testing or short-run production. It can give a company a first-to-market advantage.
The liquid poured and cured silicone molds used for casting urethane are much cheaper to produce compared to creating injection mold 'hard' tooling.
To put it in perspective, a casting project might be hundreds of dollars, compared to the thousands of dollars it would be for a comparable injection molding project.
The best method of producing parts ' urethane casting, CNC machining or injection molding ' will be determined by part quantity. For prototypes and low-quantity parts, urethane casting provides a great value because the cost is very low, yet the quality of the parts is very high.
The cast urethane process can use a variety of formulations to produce parts that are soft or hard, colored or transparent. The silicone molds provide excellent surface finish detail and can accurately mimic production textures.
In addition, parts can be over-molded, have inserts incorporated into them, and have post-process treatments like painting.
Urethane casting produces parts with physical properties on par with injection molding, and the parts are structurally superior to their 3D printed counterparts. 3D printing - despite continuous improvements - still has material and structural integrity limitations. Urethane casting, in contrast, produces high-quality, robust parts.
About Denny Scher
Denny Scher is the Marketing Manager for ICOMold, a custom digital manufacturer with customers worldwide in a variety of industries. ICOMold provides custom plastic injection molding, CNC machined plastic and metal, and urethane casting.
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