Urethane Casting
Vacuum urethane casting for low-volume production of plastic-like parts. Silicone molds replicate injection-molded aesthetics and mechanical properties without tooling investment.
About Urethane Casting
Urethane casting (vacuum casting) produces plastic parts by pouring polyurethane resin into silicone rubber molds under vacuum. The silicone molds are made from 3D-printed or CNC-machined master patterns, enabling injection-mold-quality parts without the cost and lead time of steel tooling.
FabRapid offers 15+ polyurethane resins that simulate production plastics including ABS, polypropylene, polycarbonate, nylon, and elastomers. Each resin matches the mechanical properties, color, and surface feel of the target production material, making urethane castings ideal for functional testing, market validation, and small-batch production.
Urethane casting bridges the gap between 3D printing (1-10 units) and injection molding (1,000+ units), providing production-quality parts in quantities of 10-200 from a single mold.
Key Capabilities
No Tooling Investment
Silicone molds cost $500-2,000 vs $15,000-80,000 for injection mold tooling. Each mold produces 15-25 high-quality parts.
15+ Production-Simulating Resins
Polyurethane resins that match the mechanical properties, color, and feel of ABS, PP, PC, nylon, and flexible elastomers.
Production-Quality Surface Finish
Parts replicate the exact surface finish of the master pattern — including textures, lettering, and fine details.
Custom Color Matching
Resins can be color-matched to Pantone or RAL references for market-ready prototypes and pilot production.
Technical Specifications
How Urethane Casting Works
Master Pattern Creation
A high-resolution master pattern is 3D printed (SLA) or CNC machined, then polished and finished to the exact surface quality desired on the final parts.
Silicone Mold Making
The master pattern is suspended in a casting frame and liquid silicone rubber is poured around it. After curing, the mold is cut open and the master removed, creating a precise negative cavity.
Vacuum Casting
Polyurethane resin is mixed and poured into the silicone mold under vacuum to eliminate air bubbles. The mold is heated to cure the resin, producing a part identical to the master.
Finishing & Delivery
Cast parts are removed from the mold, trimmed, and finished. Painting, pad printing, and assembly services are available.
Compatible Materials
Materials available for urethane casting.
Urethane Casting FAQ
A typical silicone mold produces 15-25 high-quality parts before the mold degrades. More complex geometries with undercuts or thin features may reduce mold life. Additional molds can be made from the same master pattern for larger quantities.
Urethane cast parts achieve similar appearance and dimensional accuracy but have slightly different mechanical properties than injection-molded thermoplastics. Polyurethane resins simulate production materials but are not identical. For functional validation, urethane casting is excellent. For production above 200 units, injection molding is more cost-effective.
Ready to Start Your Urethane Casting Project?
Upload your CAD file and get an instant quote. Most parts ship in 3-5 business days.