Urethane Casting for Aerospace & Defense | TTH

Urethane casting has long been valued for its ability to deliver durable, flexible parts for low- to mid-volume production—especially for aerospace and defense applications where injection molding may not be practical. At The Technology House (TTH), our urethane casting service focuses on delivering customized solutions that meet the mission-critical demands of aerospace and defense, where precision, durability, and compliance are imperative.

Now, with the release of our new Urethane Material Comparison Chart, it’s easier than ever to evaluate and select the ideal urethane casting materials for your unique requirements. Whether you're looking to reduce development time, test flight-ready parts, or scale into production, this tool simplifies the decision-making process.

Why Aerospace and Defense Teams Choose Urethane Casting

In aerospace and defense applications, components must consistently meet stringent quality standards and withstand harsh environments—from high altitudes and mechanical stress to chemical exposure and fluctuating temperatures. Urethane casting provides an ideal solution by offering:

• Material Versatility: From soft-touch elastomers to rigid, impact-resistant polymers, the range of available urethane casting materials supports everything from rugged field equipment to lightweight drone components.
• Design Flexibility: Urethane casting easily handles complex geometries, undercuts, and multi-part assemblies—ideal for creating lightweight, multifunctional drone housings or intricate cockpit panels.
• Size Flexibility: Unlike additive manufacturing, which is limited by machine build envelopes, urethane casting supports a broader range of sizes, from small, detailed components to larger enclosures and housings.
• Short-Run Production: When you need anywhere from a few dozen to a few hundred parts, urethane casting offers a cost-effective, high-quality solution that bridges the gap between prototyping and full-scale manufacturing.

These benefits make urethane casting a natural fit for developing and scaling UAV components, control panels, protective enclosures, and other aerospace systems.

Urethane Material Flexibility: Charting the Right Choice

TTH’s Urethane Materials Comparison Chart makes it simple to evaluate materials side by side and match them to your project requirements. A few examples include:

• TC 885 FR — An ABS-like material that is rigid, durable, and UL 94 V-0 flame-retardant; commonly used for electronic housings and cockpit components (78D hardness).
• HAPFLEX 671 — Known for elasticity, tear resistance, and high heat performance, making it a strong choice for protective covers, living hinges, and UAV fixtures (70D).
• TP-4007 — Tough and impact resistant, ideal for aerospace components requiring durability and color-matching options (75–85D).
• HAPFLEX Kits (540–580) — A family of rubber-like polyurethanes ranging from 45A–80A durometer, suited for gaskets, grips, and vibration-resistant parts.
• ESD 1085 LCFR — Designed for sensitive electronics, this material offers heat deflection, impact resistance, and UL 94 certification, while maintaining transparency.

From Prototype to Flight-Ready Part

The beauty of urethane casting is in its scalability—perfect for prototypes or low-volume production runs. Many of our aerospace and defense clients use TTH’s urethane casting service to move seamlessly from early-stage designs to flight-ready components.

Real-world applications include:

• Lightweight, durable drone housings with integrated clips and mounting features
• Custom-fit seals and gaskets for field devices
• Impact-absorbing enclosures for tactical electronics
• Ergonomic control grips for cockpit systems

To better understand how urethane casting compares to other prototyping and production methods, check out our blog on 5 Things You Need to Know About Cast Urethane.

Why TTH? Precision, Partnership, and Compliance

At TTH, we offer more than just parts, we offer partnership. Every project is assigned a dedicated project manager to keep communication clear, timelines on track, and quality consistent from start to finish. Our team works directly with yours to ensure that your urethane components meet aerospace and defense requirements without compromise.

And because we believe in personalized quoting, we don’t auto-quote or push generic solutions. Instead, we collaborate with you to recommend the right material and process to support your unique mission.

Let’s Get to Work

Ready to bring your concept to life? Our team of experts—and your dedicated project manager—are here to help you choose the right materials and process for your aerospace or defense application.

Request a personalized quote today and take the first step toward turning your design into a flight-ready part.