Design Guideline: Urethane Casting

Stratasys Direct Manufacturing offers six Urethane Casting products – QuantumCast, CompositeCast, VolumeCast, RotationCast, Engineering Grade, and CompressionCast. Learn more about our proprietary Urethane Casting methods and design considerations in the design guidelines.

QuantumCast is Stratasys Direct Manufacturing’s flagship Urethane Casting product on which we’ve built our expanded offering. QuantumCast is a proprietary multi-step technology that applies vacuum, heat and pressure to process Advanced Formula Polymers (AFP’s) yielding void-free, strong and stable preproduction and short-run production components. This low pressure injection molding into reinforced soft tools combines the benefits of platinum silicone molds (speed and versatility) with quantum improvements in mechanical properties utilizing AFP materials. Specifically, our AFP3100 has over three times the impact strength of earlier generation cast urethanes while offering excellent rigidity (high flex modulus).

CompressionCast Silicone utilizes a compression molding process with flexible silicone material. Silicone parts are ideal for button and keypad applications as well as water resistant applications.
CompositeCast, offered only by Stratasys Direct Manufacturing, was developed over a two year period with testing at six beta sites. CompositeCast takes QuantumCast to the next level by adding composite sheet material (fiberglass, carbon fiber, Kevlar, etc.) into the cavity of our precision Platinum Silicone molds. The result is a very tough and stiff composite reinforced cast urethane part with B-side detail captured. Typical cloth to resin ratios are 27 - 41%.

RotationCast is ideal for producing hollow parts or complex core geometries. RotationCast combines our premium platinum silicone molds on a multi-axis casting platform with standard QuantumCast materials.

Engineering Grade is a cost effective and quick-turnaround solution for non-cosmetic applications.

VolumeCast produces longer runs of parts at a lower per piece price point, achieved using various casting and hybrid tooling techniques that extend mold life and output. The main advantage of VolumeCast is that it can produce many parts from one tool without having to use expensive hard tooling. VolumeCast is suitable for 25 - 100 part runs and is available with Stratasys Direct Manufacturing’s AFP 4010V black material. VolumeCast projects are reviewed on a case-by-case basis for sustainability. 

Learn more about design considerations and key technology information on Urethane Casting by downloading the design guide.

Download the Design Guide

Urethane Casting Resources

emd millipore

Medical Production: EMD Millipore’s Muse Cell Analyzer

EMD Millipore utilized urethane casting for initial product launch.

EMD Millipore utilized urethane casting for initial product launch.

Read the Case Study
breaking the mold with cross technologies

Breaking the Mold with Cross Technologies

Benefit from the best of both worlds, 3D printing used with conventional manufacturing methods.

Read the Article
Urethane Casting
Urethane Casting: Prototype to Production

“It’s a great way to get parts to market without having to wait or spend the capital investing in injection molding or hard tooling.”