Urethane Casting

What is Urethane Casting

Urethane casting is a manufacturing process for creating a prototype and low-volume parts by employing a silicone mold to make urethane parts. The parts are made of materials that are plastic-like or rubber-like.

The process is often ideal for quantities up to about 25 parts, and it’s several advantages over other plastic manufacturing processes like injection molding and additive manufacturing (3D printing): it’s fast, inexpensive, and produces high-quality parts.

The urethane casting process has been used for rapid prototyping for several years to supply top quality parts cost-effectively. Urethane casting often uses urethane casting to make prototypes of parts that will eventually be injection-molded.

Many urethane casting customers don’t realize that the method also offers an excellent thanks to making production parts. For instance, A single customer can easily place an order for a large number of parts, and we will deliver them within a short time frame.

Urethane Casting Process

Urethane Casting

The cast urethane process creates a finished product by employing a cast or mold master pattern and injecting the fabric inside the mold. the fundamentals of this method simply entail bringing together two liquid materials which chemically react and form into a solid shape.

This method allows the substance to require any shape or form which will be imagined. While the essential steps appear rather simple, there are tons of hidden science and techniques behind the particular procedures.

The master pattern could also be open or closed molds, and with or without reinforcements. a couple of reasons this method is popular is to supply short-term parts, prototypes, molds or tools.

Since the resin has such a variety of properties and strengths, it’s a flexible material for a wide range of applications. A good type of kit is employed to regulate the substance and handle it appropriately. it’s necessary to regulate the temperature and rate of flow to make sure that the top product is without flaw.

There are two ways during which the cast urethane process is often conducted: with gravity-fill molds or with pressure-fill molds. Gravity molds are a rather self-explanatory method. it’s the right method for creating prototype products and products with short to medium production times.

On the opposite hand, pressure fill molds inject the substance into a mold with the utilization of kits like an injection ram or a screw-type plunger. The substance is heated during a barrel or bin and is moved with the plunger. Because the material melts, the plunger pushes it forward through a nozzle and into the mold.

After the mold cures, it’s sliced into distinct sections, and therefore, the pattern is removed. The cavity formed is employed for casting the top product. The cavity or void is crammed with insulating, which can cure and be extracted from the tool.

This process can get more complex, and tons of consideration must tend to the fabric, the master pattern, and therefore the equipment used.

Advantages of Urethane Casting?

Urethane Casting

Still not sure whether to go for the urethane casting or not? These benefits of the whole process might convince you to think otherwise.

1. Fast production

How long does urethane casting take? You may ask. The urethane casting process is an extremely fast method of manufacturing parts. This is possible because the silicone molds used to make parts via this process are created very quickly, especially compared to the hard tooling utilized in injection molding.

It’s ideal for low-volume production when quantities don’t justify investment in injection mold tooling.

If the plan is to injection mold an outsized quantity of parts, but some are needed immediately, then urethane casting may be a fast method to get first-run parts made before the assembly tooling is prepared.

It’s excellent for testing product design, for one-off products, or for testing market or consumer responses to a replacement product. With such a fast turnaround, urethane cast parts can bring a project to its next level for end-user testing or short-run production. It can provide a company with a first-to-market advantage.

2. Low cost

What is the cost of urethane casting?  Would you like to save money for producing parts and products?

The liquid poured and cured silicone molds used for casting urethane are less expensive to supply compared to making injection mold “hard” tooling.

To put it in perspective, a casting project could be many dollars, compared to the thousands of dollars, it might be for a comparable injection molding project.

The best method of manufacturing parts – urethane casting, CNC machining or injection molding – are going to be determined by part quantity. For prototypes and low-quantity parts, urethane casting provides excellent value because the value is extremely low, yet the standard of the parts is extremely high.

3. High-quality products

The cast urethane process can use a spread of formulations to supply parts that are soft or hard, colored, or transparent. The silicone molds provide excellent surface finish detail and may accurately mimic production textures.

In addition, parts are often over-molded, have inserts incorporated into them, and have post-process treatments like a painting.

Urethane casting produces parts with physical properties on par with injection molding, and therefore 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.

4. Abrasion resistance

Urethane casting results in materials that have a high resistance to abrasion. Abrasion resistance refers to the power of a material to resist wearing when it comes to direct contact with another surface. Wearing occurs when a tough, rough surface slides across a softer surface, usually the adhesive, causing the undesired removal of fabric from the surface.

5. A wide variety of finishing options

Urethane-Casted parts are often either rigid, flexible, or maybe rubber-like counting on the composition of the Urethane used.

At Roche Industry, we provide Urethane during a wide variety of color options, including translucent, black, and PMS/RAL color matching.

Parts can also be applied with a typical, smooth finish, or a custom finish, which incorporates adding hardware installations and painting.

Applications of Urethane Cast

Urethane Casting

As a method of manufacturing, urethane casting has a wide range of applications. It is used for making large and complex products or parts while at the same time small-sized parts.

The flexibility of the urethane casting resin allows it to come up with complex designs. You can also obtain different parts and decorations out of the urethane casting process.

For low and large volume production:  Let’s say you just want to produce a few units of parts for your main project.  Urethane cast can be an ideal method for producing the parts. The flexibility of this production technique allows you to control the volume of production. You can choose either large scale or small scale. With either capacity, you will be able to cut down on the wastage of the resources.

For advanced prototyping: Prototyping helps manufacturers to have a vision of how the final product will look like or even operate. Urethane casting process provides a perfect system for the advanced prototyping. Through this process, you will be in a perfect position to make all the necessary design changes when needed.

For consumer testing: Does the product meet the market standards? Urethane casting enables manufacturers to conduct consumer testing for their products. A sample of users can be allowed to test samples of products before they are officially released to the market.

Product of urethane casting

Urethane casting is used in the modern world to make a wide range of products. Some of these products include;

-Consumer electronics

-Automotive parts

-Aerospace parts and products

-Making toys

In most of these applications, the urethane cast products are used as covers seals and decorations. This explains why the cast needs to be physically and chemically strong to withstand different types of forces.

Is there any application that you think will be a perfect fit for mold casting?

Cast Urethane vs. Injection molding

The closest rival to cast urethane is the injection molding process. The two methods of manufacturing are similar in many different ways. However, there are several aspects that differentiate these two.

Urethane molding is often used for prototype, bridge, and production of low volumes from one part too many parts.

Injection molding is often used for prototype or bridge but mostly used for top volume production of hundreds to tens of thousands.

When it involves time, Urethane samples in 3-4 weeks (1-10 parts are often molded per day)

Injection-molded samples in 6-8 weeks (100’s of parts are often molded per day)

All lead times are determined by the casting material, finish, part design, and part size.

How about the cost?Urethane tooling cost range from hundreds to thousands of dollars

Injection mold tooling costs range from a few thousand to tens of thousands of dollars

Urethane molding costs are much above injection molded parts because urethane molding may be a far more labor-intensive process, while injection molding is often more automated.

When it involves tolerance, Urethane tolerances are .010” for the primary inch and .005” for each inch afterward.

Injection molding tolerances are +/.005” for the primary inch and .002” for each inch after that.

In terms of the material, Urethane molding uses polyurethanes to mimic an injection mold grade production plastic, whereas injection molding uses particular production plastics. Both processes can mold both rigid and soft durometers.

Parts are often molded in standard colors, custom color matching, and textured in both processes. Even MR, UL, and FDA materials are available for urethane also as injection molding. Additionally, both methods can over-mold onto plastic or metal components.

Urethane Casting Services in China: Roche Industry

From this guide, it is clear that the advantages of urethane casting are overwhelming. Would you like pats of your products to be manufactured to precision? Let us do the job. All you need to do is simply contact us.