Cast urethane is the process of pouring liquid polyurethane resin into a rubber mold to create a part. It is a cost-effective alternative to injection molding, making it ideal for low-volume production and prototyping.
Benefits
Low-cost tooling and design iterations with minimal rework expenses allow programs to scale from low to high volume before committing to capital tooling investments. Because rubber molds can be easily modified, design adjustments can be made quickly, making this an ideal process for prototyping.
Additionally, cast urethane is a great alternative to thermoforming, as it allows injection mold-like design details to be cast directly into the part.
Cast urethane molding is well-suited for both small and large, intricate parts. Each mold can be reused up to twenty times, making it a versatile option for short-run manufacturing.
By leveraging 3D printing to create master patterns, Mack Prototype can produce high-quality molds in weeks rather than months. Urethane molding serves as a bridge to full-scale injection molding, enabling customers to refine their designs with a production-like process at low cost before committing to high-volume production tooling.
Drawbacks
The cast urethane process requires parts to set and cool within the mold, resulting in a slower production rate of approximately one part per day. However, multiple molds can be used simultaneously to increase output, allowing for faster batch production.
Why Mack Prototype?
Mack Prototype has extensive experience with cast urethane molding, from small components to large, complex parts. The team pays close attention to detail and ensures high-quality results, prioritizing clear communication and collaboration throughout the production process, making adjustments as needed to meet our customers’ requirements efficiently.
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