Urethane Casting Production Parts in Half the Time

    What Is Urethane Casting?

    Urethane Casting is a low-mid volumes process for customers looking for high quality, precise, and consistent parts, fast.

    Stratasys Direct developed a proprietary approach to master pattern production that is guaranteed to deliver consistency and quality in your cast components.

    Urethane Casting Expertise & Capacity

    We operate the largest polymer casting enterprise in North America – both in terms of production capacity and part size capabilities.

    Urethane casting gives companies a first-to-market advantage and first shots within 7-10 business days, allowing companies to get their products on shelves long before hard-tooling for traditional injection molding could be completed.

    Accuracy & Consistency with Urethane Casting

    Get the first-to-market advantage through the use of quick-turn, 3D printed master patterns and fast curing silicone molds.


    Order Cast Urethanes
    urethane casting

    Advanced Formula Polymers (AFP)

    How Does Urethane Casting Work?

    Urethane Casting utilizes quick curing silicone molds and 3D printed master patterns.

    Proprietary Casting Method

    Our proprietary casting process is a multi-step method that applies vacuum, heat and pressure to advanced formula polymers (AFP’s).

    The process results in void-free, strong and stable production and pre-production components.

    Urethane Casting Materials

    We meet industry-specific applications and unique needs with an array of Shore A and D, flexible, rigid and foam materials.

    UL 94-VO and FAR 25.853 flame ratings, high temperature, clear and medical imaging materials are all available.

    Composite Casting

    During the casting process, sheet materials like fiberglass, carbon fiber and Kevlar can be positioned into a mold before it is filled with material.

    The resulting tough composite-reinforced cast urethane has a high flex modulus and impact strength.

    Custom Casting

    Developments in materials and molding methods enable customers to quickly manufacture high quality urethane castings.


    See Cast Urethane Materials
    urethane casting

    Controlled Casting

    Our Urethane Casting Quality Assurance

    Our Urethane Casting services are more than just a molding process – it’s a team of highly skilled operators ensuring every step of the process goes smoothly, from pattern to cast to post-processing.

    We work tirelessly to run tests and validate processes to ensure a perfect cast every time.

    Experience In Your Corner

    At Stratasys Direct, our services are backed by nearly thirty years in the industry and a team of engineers ready to assist with every step of your project.

    Our experience with Urethane Casting has led us to develop proprietary build techniques and post-processing methods.

    With quality certifications ISO 9001 and AS9100 and ITAR registration, we won’t rest until your project requirements are met.


    Make Your Cast Urethane Part
    urethane casting

    Urethane Casting Frequently Asked Questions

    How many parts can you get from a single Urethane Casting mold?

    It depends on several factors, but a Urethane Casting mold typically yields 15 to 25 parts.

    One factor that may reduce the lifespan of a mold is the geometry—sharp edges or deep undercuts tend to deteriorate more quickly.

    VolumeCast—a process that utilizes hybrid tooling and proprietary casting techniques—can have an extended mold life, up to between 35 and 75 units.

    What is the largest size of a part can you cast in urethane?

    The maximum size for a cast urethane part is approximately 1,000 cubic inches, but large parts can be reviewed on an individual basis to determine compatibility with our casting processes.

    How soon can I expect to receive a urethane part after I place an order?

    Upon receiving CAD data, typical cast urethane projects can be shipped in 7 to 10 days.


    Download Design Guidelines
    urethane casting

    “Working with the company that built the prototypes, Stratasys Direct Manufacturing, we discovered that they could meet our specs by adding a stainless steel wire mesh insert to the castings. The tooling costs are only a few hundred dollars, compared to tens of thousands of dollars for injection molding.”

    Willi Klassen, Alstom Schilling Robotics

    Urethane Casting Applications

    urethane casting production parts

    Production Parts

    Urethane casting molds can yield up to 75 repeatable production components. Read More

    urethane casting concept models

    Functional Prototyping

    Before committing to a production run, cast a true-to-product part. Read More

    urethane casting medical device housings

    Medical Device Housings

    Cast cosmetic housings for electronic medical devices with healthcare-friendly materials. Read More

    Ready to make your cast urethane application?
    Request a quote below.

    Get a Quote

    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.”

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