• Achieve Parts that Accurately Mimic the Physical Properties, Color, Texture and Feel of Injection Molded Parts

    From product development models and prototypes to low-volume production runs, Cast Urethane or Vacuum Casting is a prototyping process that uses a high-resolution master 3D print, in combination with silicone or urethane molds to produce parts that accurately mimic the color, texture, feel and physical properties of injection molded parts. 

    The Cast Urethane process also offers the ability to include additional hardware (such as thread inserts), over-mold existing parts and to include surface texture and in-mold decoration.

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About the process

Overview

From product development models and prototypes to low-volume production runs, this rapid prototyping process allows us to produce parts that accurately mimic the color, texture, feel and physical properties of injection molded parts.

  • Accurately mimic production colors and textures
  • Large material selection – rigid, flexible, durable, clear and high-temp
  • Offers similar physical properties to injection molded parts
  • Used for pre-production runs
  • Parts made for marketing samples and test prototypes
  • Low-volume manufacturing

Cast Urethane parts can be complete and delivered in days after completing SRM tooling (Silicone Rubber Molds). Short runs of several hundred pieces can be delivered within weeks in most instances.

One of the greatest benefits of the Cast Urethane process is the ability to over-mold existing parts or hardware with a second material.

Applications

Product Development

  • Industrial design parts
  • Engineering proof of concept parts
  • Mechanical breadboards
  • Performance evaluation and testing parts
  • Engineering check parts (design verification)

Sales and Marketing Samples

  • Product photo parts
  • Sales samples
  • Market study and focus group parts
  • Display models

Rapid Manufacturing/Low Volume Production

  • Medical and healthcare
  • Electronics/Connectors
  • Defense/Military hardware

Regulatory Approval Prototypes

  • UL, CE, and RoHS
  • Food grade, FDA and clinical trial
Materials
Mechanical Properties Hardness, Shore Color Tensile Strength Tensile Modulus Flexural Strength Flexural Modulus Tear Strength Elongation Izod Impact Heat Deflection Temp (@ 66 psi)
Units     psi psi psi psi psi % (ft-lb/in) ºF
ABS-Like 75 +/- 2D White 6,600 210,000 9,000 240,000 N/A 8 0.58 150º +/- 50º
PE-Like 65-68 D Light Yellow / White 2,475 45,000 N/A N/A 585 70 N/A N/A
Elastomer 90 A Neutral Tan 1.250 N/A N/A N/A 130 65 N/A N/A
80 A Opaque / White 1,900 N/A N/A N/A 131 377 N/A N/A
70 A Off-White 635 N/A N/A N/A 60 100 N/A N/A
60 A Translucent Pale Yellow 685 N/A N/A N/A 57 300 N/A N/A
50 A Neutral Tan 370 N/A N/A N/A 40 150 N/A N/A
42 A Yellow / Transparent 735 N/A N/A N/A 65 1,080 N/A N/A
32 A Light Yellow 675 N/A N/A N/A 85 950 N/A N/A
25 A Light Yellow 345 N/A N/A N/A 45 1,100 N/A N/A
PP-Like 65 D Light Yellow / White 2,475 99,000 2,875 92,850 585 70 0.85 N/A
Lexan-Like 82 D WaterClear / Colorless 6,650 260,000 11,000 320,000 N/A 5 1 158º
Glass-Filled Nylon 85+ D Opaque 9,740 207,000 12,600 350,000 N/A 8.1 0.78 150º
High Strength 84 D Light Brown 10,400 400,000 13,900 405,000 N/A 6.6 1.5 175º
RC-79D MRI Transparent 75+ D Off-White 7,000 N/A 13,000 285,000 N/A 5 N/A 140º
High Temp ABS-Like 84+ D Black 10,300 293,000 12,700 317,000 N/A 9.1 0.88 340º
94V0 Polypropylene-Like 70 D Amber 5,500 N/A 4,800 110,000 N/A 55 2.5 221º
94V0 ABS-Like 78 D White 6,100 230,000 8,600 230,000 N/A 5 0.62 195º
Finishes

Functional: Basic level of finish where functionality is more important than cosmetic appearance. Parts will be furnished flat black with a light texture. Small imperfections such as air voids, slight discoloration, parting line, gate, and vent marks, and small scratches resulting from part finishing may be visible.

Show: Premium level finish where cosmetic appearance is important. Parts can be furnished in any of our available color, sheen, and texture options. Unless otherwise specified, the part color will be flat black with a light texture. Visible cosmetic surface will be sanded smooth and painted to eliminate any visual defects. For elastomeric parts or parts which cannot be painted, small imperfections such as air voids, slight discoloration, parting line, gate, and vent marks, and small scratches resulting from part finishing may be visible. Internal surfaces will be painted to eliminate most visual defects.

Clear (Polished): Premium level finish using clear or tinted transparent materials. All surfaces will be polished smooth for clarity. Small imperfections such as air voids, slight discoloration, parting line, gate, and vent marks, and small scratches resulting from part finishing may be visible. Clear coat may be applied for clarity.

  • Documents
  • Resources
    • Ferdie Bruijnen, Vice President of Supply Chain Operations and On Demand Manufacturing at 3D Systems shares his insights on supply chain assurance, and where additive manufacturing and On Demand manufacturing fit into the equation.


Customer Stories
3D Systems' On Demand Manufacturing service quickly delivers 3D printed prototypes for rapid iteration of product design.... Read more >
“By Teaming with 3D Systems On Demand, Hammerhead Has Been Able to Change the Paradigm of Medical Education,” said Becky Delegge. “I Have Found Quickparts to Be an Asset to My Business.” ... Read more >
3D Systems On Demand Manufacturing helps packaging design firm achieve aesthetic and functional prototypes with clear SLA 3D printing ... Read more >

On Demand Services

  • Need help? We’re here.

    With advanced manufacturing facilities around the world, our team of application engineers provides industry and manufacturing expertise, all with localized support. We offer 24/7 access online, or you can contact our facilities directly and a project manager can help you with your needs.