Bridge the gap between 3D printed prototypes and high-volume injection molding. Urethane Casting is a versatile manufacturing process that uses 3D printed master patterns to create high-quality, functional parts in small to medium batches.
This technique is ideal for producing prototypes that closely mimic the look, feel, and material properties of final injection-molded plastics. It delivers production-like parts without the high cost and lead time of manufacturing steel molds, enabling realistic user testing, market validation, and functional assemblies.
High-Quality, Production-Equivalent Parts
Urethane casting produces parts with excellent surface finish, fine detail, and a professional appearance that is often indistinguishable from mass-produced items. By selecting from a wide range of polyurethane resins, you can replicate the properties of ABS, Polypropylene, Nylon, and even flexible rubber, providing a true-to-life representation of your product.
Cost-Effective for Small Batch Production
For production runs of 10 to 50+ parts, urethane casting is exceptionally cost-effective. The process uses a single, 3D-printed master pattern to create a flexible silicone mold, which can then be used to cast multiple copies. This avoids the massive upfront investment of an injection mold, making it perfect for limited editions, pilot runs, or crowdfunding reward fulfillment.
Rapid Iteration with Multiple Material Options
Need to test a part in a rigid, then a flexible, then a transparent material? A single silicone mold can be used with a variety of urethane resins. This allows for rapid, affordable material testing and design validation under different performance criteria without the need for new tooling for each iteration.
Ideal for Overmolding and Multi-Material Parts
The urethane casting process can be used to create sophisticated multi-material components, such as a rigid part with integrated soft-touch grips. Through a secondary casting step, you can overmold a flexible material onto a rigid substrate, replicating complex production techniques for prototyping and low-volume manufacturing.
Supporting Agile Product Launches in the UAE Market
For startups and established companies in the UAE’s fast-paced consumer and tech markets, speed to market is critical. Urethane casting allows you to produce high-fidelity, market-ready batches for user testing, trade shows, and early sales while your injection molds are being manufactured, ensuring you capture market opportunities without delay.
Functional Testing and Pre-Production Validation
Beyond aesthetics, cast urethane parts are robust enough for rigorous functional testing. They can be used to validate assembly processes, test for fit with other components, and endure real-world use cases. This de-risks the final transition to mass production by identifying potential issues with the design, material, or manufacturability early on.
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3DX On Demand offers complete parts manufacturing services, from 3D printed metal and plastic parts to traditional CNC, injection moulding, and cast urethane. We provide high quality parts and prototypes with some of the fastest and most reliable turnaround times in the industry. Our global network of efficient digital production facilities and manufacturing partners are able to meet the time-critical and unique business needs of today’s leading companies.
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