Urethane Casting
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What Is Urethane Casting?

urethane casted partUrethane 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.

This allows 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.

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.

Urethane Casting Materials

Advanced Formula Polymers (AFPs) will exceed your expectations for urethane casting and short-run production. Utilized for clinical trials, product testing, alpha/beta builds, prototype and end-use parts, AFP offers an unmatched selection of materials to meet your applications. Materials exhibiting properties including UL94V-0 flame rating, MRI transparency and even impact resistant composite reinforced plastics are available.



Shore D Urethane (Rigid)

Material

Description Benefits Applications Properties

AFP3100

Our high Izod impact urethane for pre-production and production applications; Certified to USP Class VI requirements and RoHS 2 / REACH SVHC Compliant
  • Extremely durable, high-impact urethane
  • Simulates ABS and PC/ABS
  • Good heat resistance
  • USP Class VI approved
  • Ruggedized covers and skins for medical equipment, scientific instruments, consumer electronics, and electronic controllers
  • Low volume production parts
DATASHEET

AFP3100FR

Our most widely used urethane for production applications with a UL 94 V-0 flammability listing at .1” thickness. RoHS 2 / REACH SVHC Compliant
  • Extremely durable, high-impact urethane with UL 94 V-0 flammability at 0.1 inch (2.6 mm)
  • Meets FAR 25.853a requirements per Appendix F, Part 1 (a1) (ii)
  • Simulates ABS and PC/ABS
  • Good heat resistance
  • Ruggedized covers and skins for medical equipment, scientific instruments, consumer electronics, and electronic controllers
  • Products requiring a UL 94 V-0 flammability rating
DATASHEET

AFP3105FR

Used for fire retardant applications in thinner sections. Meets the requirements of FAR 28.853 Part 1, (a) (1) (i) for flammability in 0.043 inch (1.1 mm) thickness; RoHS 2 / REACH SVHC
  • Passes 60 second burn test at 0.043 inch
  • Meets FAR 25.853a requirements per Appendix F, Part 1 (a1)(ii)
Durable, high-impact strength urethane with FAR 25.853 flammability rating DATASHEET

AFP3200

Provides a unique combination of physical properties for very tough and durable parts and assemblies. Good rigidity and stiffness due to its very high modulus. High tensile and impact strength for excellent resistance to breakage.
  • Provides a unique combination of physical properties for very tough and durable parts and assemblies
  • Simulates HDPE
  • Good rigidity and stiffness due to its very high modulus
  • High tensile and impact strength for excellent resistance to breakage
  • Consumer products like household goods and toys
  • Packaging such as caps, closures and cups
  • Industrial usages like piping and tanks
  • Automotive products such as wheel wells, hoods, bumpers, fenders
DATASHEET

AFP3320

Used for very high temp applications; Heat deflection of 346F at 264 psi test; RoHS 2 / REACH SVHC Compliant
  • RoHS compliant
  • High temperature cast urethane resin
  • Tough, impact resistance
  • Excellent physical properties
  • Shore 80 D
  • Ideal for high heat applications
  • HVAC
  • Underhood applications
DATASHEET

AFP3400

Used for applications that require flexibility having a low Flexural Mod. of 116,061 psi and high Izod Impact strength of 4.40ft.lbs/inch. Simulates Polypropylene. Very good impact resistance Prototype parts having mechanical properties close to polypropylene, with features requiring superior elongation like living hinges DATASHEET

AFP3600

Used for applications that require a clear material; can also be tinted easily; has good heat resistance and best for smaller geometries.
  • Excellent flexibility for clips and snap features
  • High impact resistance
  • Excellent for tinted applications
  • High reproduction accuracy
  • Excellent heat resistance
  • High transparency (clear to pale amber)
  • Lenses (tinted and clear)
  • Housings and cases
  • Backlight applications
  • Clear and frosted applications
DATASHEET

PT8958

Used primarily in production applications of medium to large parts that require MRI transparency and a UL 94V0 registered flame rating.
  • MR Transparent - the material will not image at 1.5 T in proton signal testing, with one test site showing no proton of magnetic susceptibility at both 1.5 and 3.0 T
  • UL 94 V-0 Certified (flammability testing) per IEC 60695 11-10
  • Non hand-held equipment for the MRI coil industry
  • Products requiring a UL 94 V-0 flammability rating
DATASHEET

RC 79D

Used primarily in production applications of smaller parts that require MRI transparency and a UL 94V0 registered flame rating.
  • MR Transparent
  • Tough, impact resistant material with excellent physical properties
  • UL 94-V0 flame rated
  • Many medical applications including MRI coil housings
  • Products requiring UL 94V-0 flamability rating
DATASHEET

TC885FR

High impact rigid 78 Shore D material.
  • RoHS/REACH compliant
  • Excellent for vacuum or pressure casting
  • Low viscosity
  • Computer housings
  • Models
  • Artwork
  • Electronic component enclosures
  • All types of parts requiring flame retardant characteristics
DATASHEET

CompositeCast with AFP3100FR

A glass composite sheet filled version of our most widely used urethane for production applications with a UL 94 V-0 flammability listing at .1” thickness. RoHS 2 / REACH SVHC Compliant. Parts exhibit enhanced flexural and impact properties.
  • Fast processing of parts and panels without hard tooling
  • When compared to QuantumCast, AFP3100FR used in CompositeCast experiences 163% gain in Izod Impact Strength
  • Composite-like performance (i.e., high flex modulus, high impact strength)
  • Tough and stiff cast parts
  • Medical device covers
  • Consumer electronic applications
  • Aerospace panels
  • Thin-walled cosmetic covers
  • Parts requiring high-impact strength
DATASHEET

CompositeCast with PT8958

A glass composite sheet filled version of our MRI transparent production urethane used for medium to large parts that require MRI transparency and a UL 94V0 registered flame rating. Parts exhibit enhanced flexural and impact properties.
  • Fast processing of complex parts and panels without hard tooling
  • When compared to QuantumCast, PT8958 used in CompositeCast experiences 167% gain in heat deflection temperature @ 66 psi
  • Composite-like performance (i.e., high flex modulus, high impact strength)
  • Tough and stiff cast parts
  • PT8958 meets the requirements of the UL94 V-0 specification for flammability in 1/8 inch thickness
  • Medical imaging programs
  • Medical device covers
DATASHEET


Shore A Urethane (Elastomeric)

Material

Description Benefits Applications Properties

E1005AL

Extra Soft, 5 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant
  • General purpose very soft rubber
  • Easy to pigment
  • RoHS/REACH Compliant
  • High tensile & tear strength
  • Special effects and props
  • Medical traning models
DATASHEET

E1015AL

Soft, 15 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant
  • General purpose soft rubber
  • RoHS/REACH Compliant
  • Skins and soft stretchable linings
  • Soft rubber grips
DATASHEET

E1025AL

Soft, 25 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Over molds
  • Impact absorbing pads or linings
DATASHEET

E1030AL

Soft, 30 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs/REACH Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Over molds
  • Key pads
DATASHEET

E1040AL

Medium Soft, similar to a pencil eraser 40 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Over molds
  • Key pads
DATASHEET

E1050AL

Medium Soft, similar to a Door Seal 50 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Part production, potting, molds, pigmenting
  • Special effects and props
DATASHEET

E1060AL

Medium Hard, 60 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Over molds
  • Boots
  • Bellows
DATASHEET

E1070AB

Medium Hard, similar to automotive tire tread 70 Shore A Elastomer used for production parts and special effects props; RoHs Compliant
  • General purpose rubber
  • RoHS/REACH Compliant
  • Over molds
  • Cable connectors
  • Bellows
DATASHEET

E1080AB

Hard, similar to Hydraulic O-Rings 80 Shore A Elastomer used for production parts and special effects props; RoHs Compliant
  • General purpose hard rubber
  • RoHS/REACH Compliant
  • Rollers
  • Cable connectors
DATASHEET

E1090AB

Hard, similar to a squeegee 90 Shore A Elastomer used for production parts and special effects props; RoHs Compliant
  • Hard general purpose rubber
  • RoHS/REACH Compliant
  • Rollers
  • Bumpers
DATASHEET

E1095AB

Hard, similar to a shopping cart wheel 95 Shore A Elastomer used for production parts, strain reliefs and special effects props; RoHs Compliant
  • Hard general purpose rubber
  • Very good tear resistance
  • Good abrasive resistance
  • RoHS/REACH Compliant
  • Rollers
  • Bumpers
DATASHEET


Expanding Foam

Material

Description Benefits Applications Properties

Foam-Flex V412

Flexible, Soft, variable density foam ranging from 4-12 lbs. used in special FX, medical training and prototype seat and cushion applications.
  • Low density
  • Soft feel
  • Open cell
  • Bumpers and crash pads
  • Arm rest and seat cushions
  • Movie props
  • Thermal insulation
  • Sound dampening
  • Impact protection
  • Custom packaging
DATASHEET

Foam-Flex V915

Flexible, Lively, variable density foam ranging from 9-15 lbs. used in special FX, medical training and prototype seat and cushion applications.
  • Medium density
  • Lively feel
  • Open Cell
  • Bumpers and crash pads
  • Arm rest and seat cushions
  • Movie props
  • Thermal insulation
  • Sound dampening
  • Impact protection
  • Custom packaging
DATASHEET

Foam-Flex V1232

Flexible, Tough, variable density foam ranging from 12-32 lbs. used in special FX, medical training and prototype seat and cushion applications.
  • High density
  • Firm feel
  • Self skinning
  • Bumpers and crash pads
  • Arm rest and seat cushions
  • Movie props
  • Thermal insulation
  • Sound dampening
  • Impact protection
  • Custom packaging
DATASHEET

Foam-Rigid V316

Rigid, variable density foam ranging from 3-16 lbs. used in special FX, flotation, device/equipment insulation and prototype part applications.
  • Rigid
  • Closed cell polyurethane foam
  • Available in wide density ranges
  • Thermal insulation
  • Sound dampening
  • Custom packaging
  • Encapsulation
DATASHEET


Silicone (CompressionCast Materials)

Material

Description Benefits Applications Properties

AFS15

Soft, 15 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. Platinum based silicone
  • Ink stamp pads
  • Pressure pads
  • Molds
DATASHEET

AFS30

Soft, 30 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. Platinum based silicone
  • Mold making
  • Encapsulation
  • Pressure pads
  • Gaskets
DATASHEET

AFS40

Medium Soft, 40 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. Platinum based silicone
  • Flexible buttons
  • Keypads
  • Gaskets
  • Applications where water resistance or water proofing are required
DATASHEET

AFS50

Medium Soft, 50 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. Platinum based silicone
  • Mold making
  • Encapsulation
  • Pressure pads
  • Gaskets
DATASHEET

AFS60

Medium hard, 60 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. Platinum based silicone
  • Mold making
  • Gaskets
  • Encapsulation applications
  • Pressure pads
DATASHEET

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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 Prototypes

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

Our Urethane Casting Quality Assurance

a technician casts urethane into a moldOur 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.

Not sure where to start? Our experts are here to help.

Contact an Engineer

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.”

Frequently Asked Questions About Urethane Casting

red cast urethane partHow 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.

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