Metal CNC Milling⏵
Expedited Injection Molding ⏵

Urethane Casting

What Makes Us Different?

As a urethane molding company, we know custom urethane or polyurethane casting is the ideal process to produce near-production quality parts for prototypes and other low-volume needs. Our urethane casting services utilize 3D printing and silicone rubber molds, keeping tooling costs low and turnaround times fast. The unique properties of many production-grade materials can be closely duplicated through different urethane formulations. Especially when compared to plastic injection molding, urethane casting delivers numerous advantages.

Low tooling costs

Fast turnaround times

Closely reproduce the properties of other materials

Little to no finishing required

Our Capabilities

Since the urethane casting process starts with a 3D printed master pattern and utilizes silicone rubber molds, RevPart’s capabilities are ideally suited to execute the process efficiently and with our signature commitment to quality. We are well-versed in a wide range of different materials and formulations, and will work with you to create urethane casted parts exactly to your specs.

How Does Urethane Casting Work?

Custom urethane casting makes the most of high-efficiency, low-volume processes to produce quality prototypes that can provide the most accurate representation of your finished part. Urethane injection molding starts with a 3D printed model, which is then finished to the exact specs required for the piece, eliminating later finishing steps. This 3D printed model is then surrounded by room-temperature vulcanized (RTV) rubber, which is allowed to set, forming the mold. Once the mold is set, it is cut or separated and the original 3D printed model removed, creating the cavity where the urethane will be injected. Finally, the urethane molding process is carried out much like production-level injection molding, creating the final parts.

Urethane Casting Process

Getting a quote:

At RevPart, we want your custom polyurethane molding experience to be as fast and efficient as possible, wire to wire — and that includes the quoting process. Our goal is to give you the tools you need to provide us with everything we need to get you an accurate quote, fast. Be sure to include: How many pieces you’ll need to produce, a description of the part (size, shape, features), and details on the material formulation (for instance, what material you’ll be using for your production run).

Building the mold:

Our expertise in 3D printing means that we can create a mold to urethane cast just about any part. We are experienced in using the 3D printing process in innovative ways to quickly produce even the most complex formulations. Since you’re starting with a high-quality pattern, you can rest assured that the remainder of the polyurethane injection molding process builds from there. Once the mold pouring and vulcanizing process is complete, we draw on years of experience to choose ideal placement for the gate, sprue and part lines — creating a part that’s essentially ready for shipment once cast.

Making the parts:

Designed for low-volume runs, silicone rubber molds create parts of similar quality to high-volume runs. We work with you to determine the particular material qualities you’re looking for, and formulate the urethane accordingly. The thermoset urethane is heated to cure, at which point any finishing steps, including flash and sprue trimming — usually minimal — are executed. From here, your parts are inspected by our quality engineers, and delivered to you.

Urethane Casting Options

Urethane is one of the most versatile materials available, and can be manipulated to provide a wide range of properties, textures, hardnesses and so on. At RevPart, we take pride in our versatility, and are ready to work with you to overcome any challenges in creating the parts you need.

We can produce exactly the shade that is needed through our wide variety of paints.

The urethane casting process is ideal for custom finishes and textures — due to the nature of the 3D printed original pattern and the qualities of the silicone rubber mold. We can texture the mold and part according to any SPI finish or MT finish, as well as any custom design you may require.

Urethane is versatile and able to nearly reproduce the qualities of a number of materials, including ABS, PP and PE. When ABS-like, PP-like and PE-like prototypes are needed, you save on the cost of low-volume quantities of those materials by making use of the versatility of urethane.

Value-added options:
When additional requirements beyond urethane casting are needed to create your part, we can provide them, including spray painting, pad printing, screen printing and more.