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CapabilitiesUrethane Casting Services
URETHANE CASTING SERVICES
LOW VOLUME, DURABLE PARTS WITH PRODUCTION-LEVEL QUALITY
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Urethane Casting Services
Materials
Finishes
Applications and Benefits
How It Works
Tolerances
Casting FAQ
Download Guide
URETHANE CASTING
Urethane casting provides end-use, rigid plastic parts or rubber parts with
production-level quality. Built without expensive and time-consuming hard
tooling, our urethane casting process uses a 3D printed master pattern and
silicone molds to deliver high-quality, short-run parts up to 30” long. The
finished dimensions of urethane cast parts depend on the accuracy of the master
model, part geometry, and casting material. In general, a shrinkage rate of +
0.15% is expected.
Cast urethane parts are frequently used when color, surface quality, and
toughness are required. Cast urethane is a perfect alternative for insert
molding or overmolding in low volumes with diverse material choices.
Polyurethane cast parts can also be used for bridge-tooling between a 3D printed
rapid prototype and an injection molding with a balance of quality, cost, and
time. Urethane cast parts can also be clear, color-matched, painted (including
EMI shielding), have installed inserts, and even custom finished.
New!
URETHANE CASTING MATERIALS
Cast urethane parts are often compared to injection molding materials. For
example, a stiff urethane cast part may be described as "polycarbonate-like,"
and a more flexible plastic may be "polypropylene-like." We group our urethane
materials into general categories to help you make quicker decisions and get the
best performance on your project. The list below describes the categories of
materials and technical examples when selecting polyurethanes.
Cast Urethane Materials
Material NameShore HardnessDescriptionTechnical InformationData Sheets
Material Name
General Purpose
Shore Hardness
Shore D 76-80
Description
An impact-resistant Shore 78D material used for a variety of purposes from
enclosure housings to concept models. This material exhibits ABS-like
properties.
Technical Information
TC-878, TC-852, or equivalent
Data Sheets
General Purpose Data Sheet
Material Name
Rigid Clear
Shore Hardness
Shore D 80
Description
A versatile, Shore D 80, clear polyurethane. A matte finish will give a frosted
appearance and a higher gloss will increase its transparency.
Technical Information
Poly-Optic 1410 or equivalent
Data Sheets
Rigid Clear Data Sheet
Material Name
ABS-Like, FR
Shore Hardness
Shore D 78-82
Description
A tough Shore 80D flame retardant material that is UL Listed with a flammability
rating at 1/16" (1.6 mm).
Technical Information
TC-891-FR or equivalent
Data Sheets
ABS-Like, FR Data Sheet
Material Name
Polypropylene-Like
Shore Hardness
Shore D 65-75
Description
A tough and abrasion-resistant flexible urethane with polypropylene-like
ductility.
Technical Information
TC-872, HP-2270D, or equivalent
Data Sheets
Polypropylene-Like Data Sheet
Material Name
Polycarbonate-Like
Shore Hardness
Shore D 82-86
Description
A stiff, high impact, high HDT, material with a wide variety of uses. Simulates
polycarbonate (non-clear), Shore 84D.
Technical Information
TC-854 or equivalent
Data Sheets
Polycarbonate-Like Data Sheet
Material Name
Glass-Filled Nylon-Like
Shore Hardness
Shore D 85
Description
A stiff, USP Class VI, high-performance urethane with high impact strength and a
HDT of 190°F (88°C).
Technical Information
PT8902 or PT8952 (FR)
Data Sheets
Glass-Filled Nylon-Like Data Sheet
Material Name
Rubber-Like Polyurethane
Shore Hardness
Shore A 25-95
Description
A Shore A elastomer with a high elongation to break.
Technical Information
F-130 to F-190 or equivalent
Data Sheets
Rubber-Like Polyurethane Data Sheet
Material Name
Clear Rubber-Like Polyurethane
Shore Hardness
Shore A 40-95
Description
A colorless Shore A elastomer with a high elongation to break. Matte finish will
give a frosted appearance, and higher gloss will increase its transparency.
Technical Information
WC-540 to WC-595 or equivalent
Data Sheets
Clear Rubber-Like Polyurethane Data Sheet
Available Finishes for Urethane Casted Parts
Matte/Frosted
Parts have a smooth, satin-like finish due to the master pattern being
bead-blasted matte. Clear and translucent parts with this finish will appear
frosted. Matte finishes are useful for handheld and high-touch areas as it
reduces fingerprint visibility.
Semi-Gloss
A finish that includes some sheen but not high reflectivity. Semi-gloss finishes
are in between high-gloss and matte, resulting in a smooth, easy-to-clean
surface.
High-Gloss
A highly reflective finish is made by polishing the master pattern before making
the mold. High-gloss has a high sheen and will have the highest transparency for
clear parts. High-gloss is useful for cosmetic models, cleanable surfaces, and
lenses.
Custom
Xometry can provide additional processing, including custom textures, secondary
finishes, painting, and more.
URETHANE COLOR OPTIONS
Polyurethanes can be blended with pigments to achieve a variety of colors.
Naturally, a urethane may be amber to milky-white in color. Xometry's clear
urethane options are formulated to be colorless. Below are Xometry's color
options:
* Black
* Color-Match
* Natural (unpigmented)
* Clear (colorless)
READY TO GET A URETHANE CASTING QUOTE?
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APPLICATIONS OF URETHANE CASTING
LOW-VOLUME PRODUCTION
Urethane cast parts are perfect for low-quantity production—when volumes do not
justify investment in injection mold tooling—as well as for first run production
parts, which can be completed weeks before production tooling is ready.
ADVANCED PROTOTYPING
The urethane casting process and relatively inexpensive tooling involved makes
it easy and economical to make any necessary design changes. Additionally,
different materials can be used with the same mold, making it possible to test
designs with a variety of materials.
MARKET TESTING
End-user functionality and a high-quality finish makes urethane cast parts ideal
for consumer testing, user evaluation and concept models. Using the cast
urethane process means that changes can be incorporated quickly for either
further testing or market launch.
OVERVIEW: WHAT IS URETHANE CASTING?
THE BASICS OF URETHANE CASTING
Urethane casting provides end-use, rigid, flexible, and rubber parts with
production-level quality. The urethane casting process uses a 3D-printed master
pattern to create a silicone mold that delivers high-quality, short-run parts as
an economical alternative to low-volume injection molding.
HOW URETHANE CASTING WORKS
Urethane casting is similar to injection molding in that it requires a tool with
a cavity in the shape of the final part. The major difference is that urethane
casting uses a "soft" mold made of silicone whereas injection molding using a
"hard" metal mold that has been CNC machined. The drawback to urethane casting,
then, is that the mold wears out more quickly. However, it is vastly more
cost-efficient for low-volume and prototype plastic parts that require
production-level quality and surface finishes.
The urethane casting process has 3 major steps:
1. The Master Pattern: In step one, a master pattern of the final part is made
using an additive manufacturing process. Polyjet 3D or stereolithography
(SLA) 3D printing processes are most often used due to their ability to
produce high-resolution and naturally smooth finish parts. The master
pattern is typically hand-finished to achieve optimal surface detail before
the creation of the mold tool.
2. Molding: In step two, the 3D printed master pattern is encased in liquid
silicone that cures around the pattern, with the silicone encapsulating all
the features of the printed parts. When the mold cures, it is cut into
distinct halves and the master pattern or 3D printed part, is removed. This
leaves an internal cavity perfectly shaped like the part.
3. Pouring: In the final step of the urethane casting process, liquid urethane
or silicone is poured into the silicone mold, and the mold is then placed in
a chamber to help remove air bubbles in the liquid material. For opaque
parts, the chamber is typically pressurized. For clear parts, the chamber
typically pulls a vacuum to mitigate any bubbles and increase clarity. Once
cured, the silicone halves are separated and the newly formed part is
removed. This process is repeated until the desired quantity is achieved.
BENEFITS OF URETHANE CASTING
Urethane casting has a low-cost and quick turnaround for high-quality plastic
parts compared to injection molding or 3D printing. Where injection
molding requires an expensive upfront investment for the machining of the mold,
the silicone mold required for urethane casting is inexpensive and easy to
produce. Additionally, while most 3D printing processes require extensive
post-processing to get to a near-finished state, urethane cast parts come out of
the mold ready to go. Urethane casting is an excellent choice for creating
high-quality prototypes or low-volume production of rigid, flexible, clear,
colored, or rubber-like plastic parts.
URETHANE CASTING TOLERANCES
Typically Cast Urethane Part Tolerances
DescriptionTolerance Notes
Description
Distance Dimensions
Tolerance Notes
+/- 0.010” or +/- 0.003” per inch, whichever is larger, is typical. Irregular or
overly-thick geometries may cause deviances or deflection due to shrinkage.
Description
Shrink Mitigation
Tolerance Notes
A shrinkage rate of +0.15% can be expected due to thermal expansion of the
liquid, and the response of the flexible mold.
Description
Surface Quality
Tolerance Notes
Surface finish is externally smoothed to a satin or matte surface. Grow lines
may be present on internal or difficult-to-access features. Polishing or custom
finishes must be clearly defined and agreed upon at the point of order.
Description
Feature Definition
Tolerance Notes
Sharp corners and text may appear slightly rounded.
Description
Size Recommendation
Tolerance Notes
We can offer urethane cast parts as large as 30” (0.762 m) long.
This table is based on the assumption that designs have an adequate draft,
radii, and coring for manufacturability. Please see Xometry's Manufacturing
Standards for more information on tolerances per process.
Frequently Asked Questions About Urethane Casting
Why would you choose urethane casting over 3D Printing?
One of the most critical distinctions between urethane casting and 3D printing
is material performance and quality. Urethane casting offers higher-performing
materials that can better emulate those used in commercial products. In
addition, the fit and finish are often better with urethane cast parts. If
material performance and appearance are important to you, urethane casting
should be a strong consideration.
Why would you choose urethane casting over injection molding?
The primary deciding factor between urethane casting and injection molding is
quantity. Urethane casting is an excellent option for very low quantities (e.g.,
50 pieces) of production-grade parts. Compared with urethane casting, injection
molding will have higher upfront tooling costs that may not justify a low
quantity run. Often, our customers use urethane casting as a stepping stone to
test and refine their design before they invest in an injection molding tool.
WHY CHOOSE XOMETRY FOR URETHANE CASTING?
ENDLESS OPTIONS
Choose from millions of possible combinations of materials, finishes,
tolerances, markings, and certifications for your order.
EASY TO USE
Get your parts delivered right to your door without the hassle of sourcing,
project management, logistics, or shipping.
VETTED NETWORK
We are ISO 9001:2015, ISO 13485, and AS9100D certified. Only the top shops that
apply to become Suppliers make it through our qualification process.
DOWNLOAD THE URETHANE CASTING DESIGN GUIDE
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