Low-Volume, Durable Production-Quality Components | International Prototype Pricing Covers Tariffs
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Urethane casting delivers end-use rigid plastic, rubber, and silicone components that meet production-grade quality standards. EPTAHUB stands out as a leading provider of urethane casting services, offering cost-effective solutions to align with your project timeline and budget—with prototype pricing that includes applicable tariffs. This process leverages a soft-tooling methodology, utilizing 3D-printed master patterns and RTV silicone molds to deliver professional results for low-volume production runs.
Urethane cast parts are an ideal choice when color consistency, surface finish quality, and durability are required for order quantities ranging from 1 to 100 units. For low-volume insert molding or overmolding projects that demand diverse material options, urethane molding serves as a perfect alternative. Whether bridging the gap between 3D-printed rapid prototypes and full-scale injection molding, polyurethane or silicone casting strikes an optimal balance of quality, cost-efficiency, and turnaround time. Urethane cast components can be produced in clear formulations, color-matched to specifications, painted (including EMI shielding applications), fitted with inserts, and customized with specialized finishes.
Polyurethane is a widely utilized thermoset material category celebrated for its strength, durability, abrasion resistance, and versatility. Different polyurethane formulations can replicate the properties of numerous common thermoplastics—for instance, a rigid urethane cast part may exhibit "polycarbonate-like" characteristics, while a more flexible variant can mimic polypropylene. EPTAHUB categorizes urethane materials to simplify your decision-making process and ensure your project achieves optimal performance. Below is an overview of material categories and technical examples for reference when selecting polyurethanes:
| Material Name | Shore Hardness | Description | Technical Information | Data Sheets |
|---|---|---|---|---|
| General Purpose | Shore D 76-80 | An impact-resistant Shore 78D material suitable for a wide range of applications, from enclosure housings to concept models. This formulation boasts ABS-like properties. | TC-878, TC-852, or equivalent | General Purpose Data Sheet |
| Rigid Clear | Shore D 80 | A versatile, Shore D 80 clear polyurethane. A matte finish creates a frosted look, while a higher gloss level enhances its transparency. | Poly-Optic 1410 or equivalent | Rigid Clear Data Sheet |
| ABS-Like, FR | Shore D 78-82 | A robust Shore 80D flame-retardant material with a UL Listing and a flammability rating for 1/16" (1.6 mm) thickness. | TC-891-FR or equivalent | ABS-Like, FR Data Sheet |
| Polypropylene-Like | Shore D 65-75 | A tough, abrasion-resistant flexible urethane offering polypropylene-like ductility | TC-872, HP-2270D, or equivalent | Polypropylene-Like Data Sheet |
| Polycarbonate-Like | Shore D 82-86 | A stiff, high-impact heat deflection temperature (HDT) material with a high diverse applications, mimics non-clear polycarbonate at Shore 84D. | TC-854 or equivalent | Polycarbonate-Like Data Sheet |
| Glass-Filled Nylon-Like | Shore D 85 | A rigid, USP Class VI high-performance urethane featuring high impact strength and an HDT of 190°F (88°C). | PT8902 or PT8952 (FR) | Glass-Filled Nylon-Like Data Sheet |
| Rubber-Like Polyurethane | Shore A 25-95 | A Shore A elastomer with excellent elongation at break. | F-130 to F-190 or equivalent | Rubber-Like Polyurethane Data Sheet |
| Clear Rubber-Like Polyurethane | Shore A 40-95 | A colorless Shore A elastomer with high elongation at break. A matte finish results in a frosted look, while increased gloss boosts transparency. | WC-540 to WC-595 or equivalent | Clear Rubber-Like Polyurethane Data Sheet |
Silicone is not only a key material for creating casting tools but also an exceptional choice for end-use parts. Renowned for its durability, flexibility, tear resistance, inert nature, easy cleanability, and high-temperature tolerance, silicone rubber can achieve ultra-soft durometers as low as Shore A 10 up to medium-hard formulations in the Shore A 60 range. Silicone casting is particularly well-suited for medical devices, surgical models, props, soft-touch housings, kitchen accessories, and more.
Parts feature a smooth, satin-like finish achieved by bead-blasting the master pattern to a matte texture. Transparent and translucent components with this finish will appear frosted. Matte finishes are ideal for handheld devices and high-touch surfaces, as they minimize fingerprint visibility.
Semi-gloss finishes offer a subtle sheen without high reflectivity. Positioned between high-gloss and matte options, they deliver a smooth, easy-to-clean surface.
A highly reflective glossy finish requires polishing the master pattern prior to mold creation. This finish offers maximum sheen and optimal transparency for clear parts, making it perfect for cosmetic models, easy-to-clean surfaces, and lenses.
Texture is applied to the master pattern via painting and manual techniques before soft tooling production. Texturing enhances grip on high-use surfaces (such as handles) and reduces the appearance of fingerprints or scuff marks.
EPTAHUB provides additional processing options, including secondary finishes, painting, and other customizations to meet specific project requirements.
Polyurethanes can be blended with pigments to achieve a wide range of colors. Naturally, urethane may range from amber to milky-white. EPTAHUB’s clear urethane formulations are designed to be colorless. Available color options include:
Urethane cast parts excel in low-quantity production scenarios—where the volume does not justify the investment in injection mold tooling—as well as for initial production runs, which can be completed weeks ahead of full production tooling readiness.
The urethane casting process, combined with relatively low-cost tooling, enables easy and economical design modifications. Additionally, multiple materials can be used with the same mold, allowing for material testing across various design iterations.
End-user functionality and high-quality finishes make urethane cast parts ideal for consumer testing, user evaluations, and concept models. The urethane casting process facilitates quick design adjustments, supporting both further testing and timely market launches.
Urethane casting produces end-use rigid, flexible, and rubber components that meet production-level quality standards. The process uses a 3D-printed master pattern to create a silicone mold, delivering high-quality, short-run parts as a cost-effective alternative to low-volume injection molding.
Urethane casting shares similarities with injection molding in that both require a tool with a cavity shaped like the final part. The key difference lies in the mold material: urethane casting uses a "soft" silicone mold, while injection molding relies on a "hard" CNC-machined metal mold. While silicone molds have a shorter lifespan compared to metal molds, urethane casting offers significant cost advantages for low-volume production and prototype plastic parts that demand production-grade quality and surface finishes.
Compared to injection molding or 3D printing, urethane casting offers low-cost, quick-turnaround production of high-quality plastic parts. Unlike injection molding, which requires a substantial upfront investment in mold machining, silicone molds for urethane casting are affordable and easy to produce. Additionally, while most 3D printing processes require extensive post-processing to reach a near-finished state, urethane cast parts are ready for use immediately after removal from the mold. Urethane casting is an excellent choice for creating high-quality prototypes or low-volume production runs of rigid, flexible, clear, colored, or rubber-like plastic components.
| Description | Tolerance Notes |
|---|---|
| Distance Dimensions | Standard tolerance is +/- 0.010" or +/- 0.003" per inch (whichever is larger). Irregular or excessively thick geometries may cause deviations or deflection due to shrinkage. |
| Shrink Mitigation | A shrinkage rate of +0.15% is typical, resulting from the thermal expansion of the liquid material and the flexibility of the silicone mold. |
| Surface Quality | Exterior surfaces are smoothed to a satin or matte finish. Flow lines may be present on internal or hard-to-access features. Polishing or custom finishes must be clearly defined and agreed upon at the time of order. |
| Feature Definition | Sharp corners and text may appear slightly rounded. |
| Size Recommendation | EPTAHUB can produce urethane cast parts up to 30" (0.762 m) in length. |
This table assumes designs include adequate draft angles, radii, and coring for manufacturability. For more detailed information on process-specific tolerances, refer to EPTAHUB's Manufacturing Standards.
A key distinction between urethane casting and 3D printing lies in material performance and quality. Urethane casting offers higher-performance materials that closely mimic those used in commercial products, along with superior fit and finish. If material performance and visual appearance are critical to your project, urethane casting is a strong consideration.
The primary factor differentiating urethane casting from injection molding is production quantity. Urethane casting is an excellent option for very low quantities (e.g., 50 units) of production-grade parts. In contrast, injection molding requires higher upfront tooling costs that may not be justifiable for low-volume runs. Many Eptahub customers use urethane casting as a stepping stone to test and refine their designs before investing in injection molding tooling.
EPTAHUB’s pricing for internationally produced prototype parts includes applicable tariffs. For more details, refer to our article on understanding international shipping costs.
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EPTAHUB holds ISO 9001:2015, ISO 13485, and AS9100D certifications.
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