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USA & Canada
USA & Canada

Urethane Casting

Parts On Demand

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What Is Urethane Casting?

Urethane 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. L 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.

Shore D Urethane (Rigid)

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AFP3100

Our high Izod impact urethane for pre-production and production applications; Certified to USP Class VI requirements and RoHS 2 / REACH SVHC Compliant

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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

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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

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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.

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AFP3320

Used for very high temp applications; Heat deflection of 346F at 264 psi test; RoHS 2 / REACH SVHC Compliant

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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.

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AFP3600

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

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PT8958

Used primarily in production applications of medium to large parts that require MRI transparency and a UL 94V0 registered flame rating.

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RC 79D

Used primarily in production applications of smaller parts that require MRI transparency and a UL 94V0 registered flame rating.

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TC885FR

High impact rigid 78 Shore D material.

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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.

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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.

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Shore A Urethane (Elastomeric)

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E1005AL

Extra Soft, 5 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant

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E1015AL

Soft, 15 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant

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E1025AL

Soft, 25 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant

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E1030AL

Soft, 30 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs/REACH Compliant

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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

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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

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E1060AL

Medium Hard, 60 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant

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E1070AB

Medium Hard, similar to automotive tire tread 70 Shore A Elastomer used for production parts and special effects props; RoHs Compliant

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E1080AB

Hard, similar to Hydraulic O-Rings 80 Shore A Elastomer used for production parts and special effects props; RoHs Compliant

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E1090AB

Hard, similar to a squeegee 90 Shore A Elastomer used for production parts and special effects props; RoHs Compliant

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E1095AB

Hard, similar to a shopping cart wheel 95 Shore A Elastomer used for production parts, strain reliefs and special effects props; RoHs Compliant

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Silicone (Compression Cast Materials)

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AFS15

Soft, 15 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets.

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AFS30

Soft, 30 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets.

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AFS40

Medium Soft, 40 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets.

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AFS50

Medium Soft, 50 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets.

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AFS60

Medium hard, 60 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets.

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Urethane Casting Applications

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Production Parts

Urethane casting molds can yield up to 75 repeatable production components.

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Functional Prototypes

Before committing to a production run, cast a true-to-product part.

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Medical Device Housings

Cast cosmetic housings for electronic medical devices with healthcare-friendly materials.

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Our Urethane Casting Quality Assurance

Our 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.

General questions? Engineering questions? Need help with your design?

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Frequently Asked Questions About Urethane Casting

How 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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