Fathom Precision prototype manufacturing company provides urethane casting services with a wide range of selection of polyurethane casting services, custom cast urethane molding services and cast urethane prototypes services, in addition with CNC machining material with ABS like, PP like, PC like, PMMA like, Rubber like to cope with various category of toys, electronic, automotive, food container, household, custom cast polyurethane parts&products and industrial sectors involving measurement with 2D optical projector and CMM measuring machines, height gauge, micrometer, roughness and impact testing up to customer’s requirement.
The core material for urethane casting is polyurethane resin, a polymer composed of two main components: a polyol and an isocyanate. These components react chemically when mixed, initiating the curing process that transforms the liquid resin into a solid, durable material.
Variety of Formulations:
Urethane casting materials come in a variety of formulations, allowing for customization based on specific project requirements. Different formulations offer varying degrees of hardness, flexibility, and heat resistance.
Urethane casting resins are often available in a range of colors, enabling the production of parts in desired hues without the need for additional painting or finishing. This is advantageous for creating visually accurate prototypes.
Fillers and Additives:
Manufacturers can enhance the properties of urethane casting materials by incorporating fillers and additives. These additives may include reinforcing agents, flame retardants, or UV stabilizers, depending on the desired characteristics of the final product.
Hardness and Shore Durometer:
Urethane casting materials are categorized by hardness, measured on the Shore durometer scale. Different projects may require materials with specific durometer ratings, ranging from soft and flexible to rigid and tough.
One of the key advantages of urethane casting is its ability to mimic the elastomeric properties of rubber. This makes it suitable for creating flexible components such as gaskets, seals, and soft-touch features.
Some formulations of urethane casting materials offer high-temperature resistance, allowing the production of parts that can withstand elevated temperatures without compromising structural integrity.
Mold Release Compatibility:
Urethane casting materials are designed to work well with various mold release agents, facilitating the demolding process. This compatibility contributes to the ease of creating intricate and detailed parts.
Certain urethane casting materials are formulated to provide optical clarity, making them suitable for applications requiring transparent or translucent components, such as lenses or light guides.
Depending on the specific material and project requirements, post-curing options may be available. Post-curing can enhance the material's properties, such as increasing its strength or improving its resistance to environmental factors.
Functional Prototypes: Urethane casting produces functional prototypes that closely resemble the properties of final injection-molded parts, allowing engineers to test and refine designs effectively.
Soft-Touch Components: The ability of urethane casting to mimic the elastomeric properties of rubber makes it ideal for creating soft-touch grips, handles, and other components in consumer products.
Flexible Components: Urethane casting is used in the medical field to create flexible components for devices such as gaskets, seals, and ergonomic handles.
Interior Components: Urethane casting is employed to produce interior automotive components like dashboards, knobs, and handles, providing durability and a realistic look and feel.
Complex Parts: Urethane casting allows for the production of intricate and complex aerospace components for prototyping and testing purposes before committing to full-scale production.
Custom Housings: Urethane casting is utilized to manufacture custom enclosures and housings for electronic devices, providing protection and precise fits.
Scale Model Production:
Architectural Models: Architects and designers use urethane casting to create highly detailed architectural scale models for presentations and client visualization.
Urethane casting, also known as polyurethane casting, is a widely used custom rapid prototyping technique that offers an efficient and cost-effective way of producing high-quality parts. This process is particularly beneficial for creating prototypes, models, and small series of functional cast polyurethane parts. The urethane casting process can be broken down into three main steps: the preparation of casting resins, the filling of resin into a silicon mold inside a vacuum chamber, and the removal of the casted part from the silicon mold after curing.
Casting resins preparation
These resins are typically two-part systems consisting of a polyol and an isocyanate. When these two components are mixed together, a chemical reaction occurs, resulting in the formation of a polyurethane plastic. The properties of the final product, such as hardness, flexibility, and color, can be adjusted by varying the types and proportions of the components used.
Resin filling into silicon mold inside the vacuum chamber
The use of a vacuum chamber is critical in this urethane casting process as it helps to eliminate any air bubbles that may have been introduced during the mixing process. These air bubbles can lead to defects in the final cast polyurethane products, such as voids or surface imperfections. The resin is poured into the silicon mold, and the vacuum is applied to draw the resin into all the details of the mold. This ensures that the final product accurately replicates the original model in every aspect.
Remove casted part from silicon mold after curing
The curing process involves the resin hardening to form the final product. The length of the curing process can vary depending on the specific resin used, but it typically takes a few hours to a few days. Once the polyurethane casting part has fully cured, it can be carefully removed from the silicon mold. The mold can then be reused to produce more parts, making urethane casting an efficient method for producing multiple copies of the same part.
Urethane casting service is not only about creating functional parts but also about achieving an aesthetically pleasing finish. The decoration of urethane casting involves several processes, including polishing, sandblasting, spray painting, and EMI shielding coating.
Polishing to smooth finishing
The first step in the decoration process is polishing. This is done to give the casted part a smooth and shiny finish. Polishing involves the use of abrasive materials to remove small imperfections and rough spots on the surface of the part. This process can be done manually or using automated machinery. The result is a part that not only functions well but also has a visually appealing, smooth finish.
Sandblasting to achieve textured finishing
If a textured finish is desired, the part undergoes a process known as sandblasting. This involves blasting the part with small particles, such as sand or glass beads, under high pressure. The impact of these particles on the surface of the part creates a rough, textured finish. This can be particularly useful for parts that need to be gripped or for aesthetic purposes.
Spray painting per customer's requirement
To add color or to protect the part from environmental factors, spray painting is often employed. This process involves applying a coat of paint to the part using a spray gun. The color and type of paint can be customized according to the customer's requirements. This allows for a high level of customization of urethane casting companies and can help the part to blend in or stand out, depending on its intended use.
EMI shielding coating
In some cases, the cast polyurethane parts may need to be protected from electromagnetic interference (EMI). This is particularly important for parts used in electronic devices. To achieve this, an EMI shielding coating is applied. This coating is typically made from a material that can block or reduce the amount of electromagnetic radiation that can pass through it, thereby protecting the part and the device it is used in.