Polyurethane casting service

DDPROTOTYPE’s polyurethane casting service (Urethane Casting Service) is a multi-step process that applies vacuum, heat and pressure to advanced formulated polymers. Polyurethane casting uses fast curing silicone mold and 3D printing master mold. This process can produce void free, firm and stable production and pre production components. Polyurethane castings provide end use, rigid or flexible plastic parts with production level quality. Our polyurethane casting process does not need to be made of expensive and time-consuming hard molds. It uses 3D printed master molds and silicone molds to provide high-quality, short-term parts up to 30 inches long. The final size of polyurethane casting depends on the accuracy of the model, the geometry of the part and the casting material. In general, shrinkage is expected to be + 0.15%.

General Tolerance

  • Usually ± 0.010 inch or ± 0.003 inch per inch, whichever is larger. Irregular geometry or excessive thickness may cause deformation or deflection due to shrinkage.

  • Due to the thermal expansion of the liquid and the response of the flexible mold, the expected shrinkage is + 0.15%.

  • Surface finish is smooth from outside to satin or frosted surface. Internal or inaccessible features may grow. Ddprototype polyurethane casting process can avoid defects, which is the result of many years of experience.

  • DDPROTOTYPE can provide polyurethane castings up to 30 inches long.

polyurethane-casting-prototype

DDPROTOTYPE recommends a minimum wall thickness of 0.040 inch (1 mm). However, in some cases, the wall on the small part may be thinner, down to 0.020 inch (0.5 mm). The larger the part, the larger the wall should be to ensure proper support. Although the casting process can change the wall thickness of the whole part, uniform wall thickness will reduce the risk of deformation due to shrinkage and stress during curing. The design wall thickness shall be at least 0.020 inch or 0.040 inch depending on the size of the entire part to ensure proper support.

COLORS AND FINISHES

Standard
Standard

Pigment is added to the liquid polyurethane prior to casting, so each casting has as-molded color. Customers may provide Pantone code for approximate color matching.

Precise-Color-Match
Precise Color Match

Paint is recommended for parts that require exact color matching. Very light colors or specific shades of white may only be achievable with painting. Pantone code or sample swatch must be provided for precise color matching.

Custom-Texture
Custom Textures

A variety of textures can be achieved by texture painting the master prior to mold making or by painting the parts after casting.

Polyurethane casting material

We use a series of shore A and D, flexible, rigid and foam materials to meet industry specific applications and unique needs. UL 94-vo and far 25.853 flame retardant, high temperature, transparent and medical imaging materials are available. In the casting process, glass fiber, carbon fiber and other sheet materials can be put into the mold before filling materials. The cast polyurethane reinforced by the tough composite has high flexural modulus and impact strength.

Shore D Urethane (Rigid)

MATERIAL

DESCRIPTION

BENEFITS

APPLICATIONS


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


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


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


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


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


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


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


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


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


U0080DC-L

Used for applications that require a clear material; can also be tinted easily; has good heat resistance and best for larger geometries.

· Water clear

· Tintable

· Excellent impact strength

· Good weatherability

· Larger parts

· Complex geometries


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


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

Shore A Urethane (Elastomeric)

MATERIAL

DESCRIPTION

BENEFITS

APPLICATIONS

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

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

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

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

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

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

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

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

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

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

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

Industries we work with
Used in a wide variety of industries

Architecture & Construction
Industrial design & Manufacturing
Medical & Life Sciences
High Tech & Consumer
Industrial Products, Mold Tool & Die
  • Model making

  • Urban planning

  • Concepts

  • Aerospace

  • Automotive

  • Defense

  • Industrial equipment

  • Marine and offshore

  • Oil and gas

  • Anatomical models

  • Medical devices

  • Orthopedics

  • Prosthetics

  • Surgical planning models

  • Aesthetic and function testing

  • Concepts and prototypes

  • Sales and marketing models

  • Jigs, fixtures, and assembly tooling

  • Injection molding

  • Silicone molding

  • Sand and investment casting

  • Thermoforming

Our polyurethane casting quality assurance

The technicians cast polyurethane into the mold, not only limited to the superb molding process. DDPROTOTYPE also has a highly skilled operation team to ensure that every step from mold to casting to post-processing goes smoothly. We work tirelessly on the testing and validation process to ensure that every time we cast it perfectly.

At DDPROTOTYPE, our service has been supported by the industry for nearly 15 years, and a team of engineers is ready to help you with every step of your project. Our experience in polyurethane casting enables us to develop proprietary casting technology and post-treatment methods. Ddprototype has passed the quality certification of ISO 9001, and we will meet your project requirements.

polyurethane-casting
MEDICAL-PROTOTYPE-SHELLS

Typical case – Custom shell

Whether you are looking for void free, solid, waterproof or highly decorative parts, we have the right technology and materials to provide customized housings that meet your specifications. Specialized in assembly and assembly inspection, we can guarantee perfect seam alignment from the smallest components to the large panel.

Our CNC processing and 3D printing technology and proprietary polyurethane casting process can produce precise shells with excellent strength to weight ratio and durability. We create custom housings for consumer electronics, medical devices, auto parts, sports equipment, aerospace components, MRI and CT scanners, and heavy construction equipment.

With a large number of rigid and flexible material libraries of various colors, our manufacturing process can produce high decorative parts. Other post-processing and finishing can also be carried out. Our professional assemblers also provide bonding services and add inserts and other hardware according to customer requirements.

Common problems in casting of ethyl carbamate

Urethane casting how many parts can a polyurethane casting mold provide?

It depends on several factors, but polyurethane molds usually produce 15 to 25 parts. One factor that may reduce mold life is geometry – sharp edges or deep undercuts tend to reduce the number of parts copied. The use of hybrid tools and proprietary casting processes can extend mold life by up to 35 to 75 units.

What is the largest part size you can cast with urethane?

Casting carbamate parts have a maximum size of about 1000 cubic inches, but larger parts can be inspected separately to determine compatibility with our casting process.

How long does it take to receive urethane parts after placing an order?

After receiving CAD data, typical casting polyurethane projects can be delivered within 7 to 10 days.