Urethane casting provides a practical alternative when you need multiple parts that replicate production material performance or support low-volume production. This process is commonly used to bridge the gap between rapid prototyping technologies like stereolithography (SLA) and hard tooling for injection molding because it avoids the high tooling costs of injection molding while enabling low-volume production using a reusable urethane mold.
At The Technology House (TTH), we provide urethane casting services that support functional validation parts and low-volume production runs across a wide range of industries.
Our engineers and project managers assist with selecting the appropriate process, urethane molding material, and finishing options to meet the performance and aesthetic requirements of your application.
These industries frequently rely on custom-molded urethane parts when functional testing or small production runs are required.
First, a master pattern must be created. At TTH, we typically produce a master pattern using 3D printing from a CAD model.
If a CAD model does not exist, we can use an existing part as the master pattern.
In both cases, the printed or physical part is used to create the urethane mold. Master patterns receive a mold-ready finish, allowing the part to be removed easily from the mold.
This surface finish is critical because the master pattern’s finish transfers directly into the final urethane casting. If a specific finish is required—such as gloss or texture—it is applied to the master before the mold is created.
The molds created in cast urethane molding are soft tools, typically made from silicone or urethane materials. These temporary molds allow manufacturers to produce multiple parts without investing in hard tooling.
Several mold options are available:
Material selection is the most important factor in urethane casting services.
There are hundreds of available materials designed to deliver specific mechanical and visual properties. These materials can range from 20A elastomers to 90D rigid plastics, allowing engineers to match the performance characteristics required for their application.
Depending on industry requirements, materials may include:
Our team can also apply custom colors, textures, and finishes to custom molded urethane parts directly from the mold or through additional finishing processes.
A project manager will work with you to ensure the material selection meets all requirements for performance, quality, cost, and delivery.
From design to production, our engineering team is ready to help bring your idea to life using professional urethane casting services.
There are hundreds of materials available for urethane molding, covering a wide range of durometers, colors, and performance specifications. Most materials can also be color-matched to Pantone standards.
Some of the materials we commonly use include:
Other material and finishing options are also available. Contact our project management team to review the best materials for your application.
Cast urethane molding is a flexible manufacturing process that can easily produce undercuts, thick sections, varying wall thicknesses, and parts without draft angles.
Standard guidelines include:
Our experts have a proven history of providing innovative solutions at every stage of product development—from product design through production.
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