{"id":2497,"date":"2021-03-22T02:40:00","date_gmt":"2021-03-22T02:40:00","guid":{"rendered":"https:\/\/sybridge.com\/?p=2497"},"modified":"2023-06-23T19:12:36","modified_gmt":"2023-06-23T19:12:36","slug":"benefits-urethane-casting-vs-injection-molding","status":"publish","type":"post","link":"https:\/\/sybridge.com\/benefits-urethane-casting-vs-injection-molding\/","title":{"rendered":"Five Surprising Benefits of Urethane Casting"},"content":{"rendered":"\n

Originally published on fastradius.com on March 22, 2021<\/em><\/p>\n\n\n\n

Urethane casting<\/a>\u00a0is a useful manufacturing method that involves creating a silicone mold from a master pattern, which is essentially a replica of the final part. The mold is then filled with a shot of urethane casting resin and allowed to cure. Once the part has cooled, it can be ejected and the mold refilled. This allows for high-quality parts to be created quickly and cost-effectively, especially when used to produce parts in relatively low volumes.<\/p>\n\n\n\n

It\u2019s unfortunate that many product teams are not familiar with the process or aware that it can be a viable manufacturing method \u2014 in fact, many who are familiar with urethane casting only see the process as a\u00a0bridge tooling method\u00a0on the path to producing end-use parts via injection molding. In any case, teams often overlook the breadth of advantages and value propositions that urethane casting offers as an end-use manufacturing method. Here are five benefits of urethane casting:<\/p>\n\n\n\n

1. Reduced Tooling and Part Costs<\/h2>\n\n\n\n

Urethane-cast parts are typically more cost-effective to produce on a per-unit basis than those made through\u00a0additive manufacturing methods, as order volume increases.<\/p>\n\n\n\n

During prototyping, additive processes may require multiple build cycles to create a higher number of parts, which adds to the overall cost of production. Urethane casting, on the other hand, can be used to\u00a0rapidly fabricate prototypes, avoiding the need for additional \u2014 and costly \u2014 build cycles.<\/p>\n\n\n\n

The cast urethane molding process also uses silicone, which makes it far more affordable than the\u00a0hard tooling\u00a0needed to create the durable metal molds used in\u00a0injection molding<\/a>. Silicone molds can be fabricated in as little as 24 hours for hundreds or thousands of dollars (depending on the size and design of the given\u00a0 mold), whereas\u00a0aluminum and steel mold<\/a>\u00a0tooling may require weeks and tens of thousands of dollars to finish.<\/p>\n\n\n\n

2. Increased Design Flexibility<\/h2>\n\n\n\n

Urethane casting is highly flexible with regard to part material; product development teams have hundreds of different materials in all sorts of colors and durometers to choose from. And in contrast to the many rigid\u00a0thermoplastics and thermosets<\/a>\u00a0used in manufacturing, silicone urethane casting resins are softer and more flexible, which makes the molds more forgiving.<\/p>\n\n\n\n

For instance,\u00a0draft angles\u00a0(which must be incorporated into mold design to allow parts to be ejected without damage) are no longer necessary with molds made from\u00a0elastomeric materials\u00a0like silicone. This allows designers to incorporate features into parts that would otherwise be impossible to achieve without\u00a0expensive slides and actions, including\u00a0undercuts\u00a0and\u00a0overmolds.<\/p>\n\n\n\n

Furthermore, design changes can be easily incorporated into mold designs based on the results of prototype testing or consumer feedback without the expense of hard tooling. Because silicone molds have a lifetime of 25-30 shots, modifications can be easily integrated between molds at a minimal expense. This does create the need for additional molds as production volume increases, but, as mentioned, silicone molds can be produced at a fraction of the cost of hard molds.<\/p>\n\n\n\n

3. Impressive Speed of Production<\/h2>\n\n\n\n

Silicone molds are much faster to produce than hard tools, with some molds being ready to use within 24 hours of being poured. Thanks to this speed, urethane casting is ideal for producing parts in lower volumes that would not justify the significant investment of a metal injection mold.<\/p>\n\n\n\n

The process can also be used as a bridge to production if parts are needed immediately, enabling product teams to begin fabricating first-run parts while the hard tools are finalized. The majority of cast urethane parts can be shipped to market within two to four weeks, giving savvy manufacturers a valuable competitive edge.<\/p>\n\n\n\n

\"\"
Urethane casting is ideal for producing parts in lower volumes that would not justify the significant investment of a metal injection mold.<\/em><\/figcaption><\/figure>\n\n\n\n

4. High Precision and Quality<\/h2>\n\n\n\n

Urethane casting enables manufacturers to create high quality parts in a variety of shapes, sizes, and materials \u2014 all with good tolerances. Typical tolerances are +\/- .020\u2033 per inch for cast urethane parts, though tolerances are still dependent on part geometry and other factors.<\/p>\n\n\n\n

Deviances to normal tolerances may be caused by the thermal interaction between the liquid shot and the silicone mold. In general, teams should anticipate a material shrinkage rate of +0.15%, meaning the volume of the part will increase.<\/p>\n\n\n\n

Further, it\u2019s worth noting that many polyurethane casting resins are capable of providing chemical and physical properties comparable or superior to production-grade plastics. In contrast to additive technologies, which are limited in some material and structural ways, urethane casting allows for the rapid production of strong, high-quality end-use parts made of a wide variety of materials.<\/p>\n\n\n\n

5. Excellent Surface Finish<\/h2>\n\n\n\n

Much like injection-molded parts, cast urethane parts offer excellent surface finish, and can be customized to include colors, surface textures, or post-production processes like painting. These options guarantee that parts will remain aesthetically pleasing even if they should be damaged or scratched during use. Urethane can be used to create parts featuring mechanical properties comparable to materials ranging from rigid plastic to rubber-like elastomer. Many materials are available in a breadth of translucencies, as well.<\/p>\n\n\n\n

Discover Efficient, Affordable Part Production<\/h2>\n\n\n\n

When it comes down to urethane casting vs. injection molding, additive manufacturing, or any other process, there are a few key factors to consider. If a large number of prototypes is needed quickly, urethane casting\u2019s speed and design flexibility make it a very compelling option. At the same time, if order volumes are huge, then urethane casting is an excellent way to beat competitors to the market until production tooling is ready.<\/p>\n\n\n\n

The speed and affordability of urethane casting make it an exceptionally useful means of production that offers a range of benefits to product teams of all kinds. Partnering with an experienced manufacturing team is the best way to ensure you\u2019re taking advantage of all the value-adds of urethane casting and optimizing your product development process.<\/p>\n\n\n\n

SyBridge is a cutting-edge on-demand digital manufacturing platform reimagining what\u2019s possible in modern manufacturing. Our design and production capabilities are backed by decades of experience, and we specialize in doing the previously undoable \u2014 usually faster and more efficiently than our customers expect.\u00a0Contact us today<\/a>\u00a0to get started.<\/p>\n","protected":false},"excerpt":{"rendered":"

Originally published on fastradius.com on March 22, 2021 Urethane casting\u00a0is a useful manufacturing method that involves creating a silicone mold from a master pattern, which is essentially a replica of the final part. The mold is then filled with a shot of urethane casting resin and allowed to cure. Once the part has cooled, it […]<\/p>\n","protected":false},"author":20,"featured_media":2579,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[38],"tags":[83],"class_list":["post-2497","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-articles","tag-urethane-casting"],"acf":[],"yoast_head":"\nFive Surprising Benefits of Urethane Casting - SyBridge Technologies<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/sybridge.com\/benefits-urethane-casting-vs-injection-molding\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Five Surprising Benefits of Urethane Casting - SyBridge Technologies\" \/>\n<meta property=\"og:description\" content=\"Originally published on fastradius.com on March 22, 2021 Urethane casting\u00a0is a useful manufacturing method that involves creating a silicone mold from a master pattern, which is essentially a replica of the final part. 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