Urethane Casting

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Urethane casting on fast forward! InterPRO manufactures plastic parts with material properties similar to engineered production plastics. This bridge-tooling method is often used to span the low volume step between prototypes and production. RTV (Room Temperature Vulcanized) Tooling and Urethane Casting are when parts are cast from liquid plastic into low-cost room temperature vulcanized rubber molds.

To produce molds using the Urethane Casting process, a master pattern is made with Rapid Prototyping or CNC. The master pattern can be finished with texturing which will be reflected in the cast parts. Liquid silicone rubber is poured around the master pattern. The mold, once cured, is cut open to remove the master pattern. The mold is then used to cast the urethane parts.

InterPRO casts all parts under computer control in a vacuum. The result is void-free castings with consistent properties. Gates, sprues and parting lines are placed specifically to optimize the final parts. Colors are cast in to match specifications. Paint, texturing and/or graphics can be added to mimic the properties of injection molded parts.

Benefits & Applications

  • Low volume production
  • Product development
  • Sales and marketing samples
  • Industrial design models
  • Engineering proof of design
  • Engineering check models design (design verification)
  • Product photo models

Cast Urethane Case Study: The Titan Medical Patient Cart


Material Overview Tensile Strength Flexural Modulus Elongation Izod Impact HDT Notes
RPU 48 A Shore 60 D material that mimics the flexibility of polyethylene 3,400 psi (23 mpa) 48,500 psi (468 mpa) 40% 2.4 178 F RoHS compliant
RPU 70 A very high impact, Shore 70 D material 4,900 psi (33 mpa) 70,000 psi (482 mpa) 320% 16.5 N/A RoHS compliant
RPU 110-FR High impact, PP-like material that is FR rated. 5,500 psi (27 mpa) 110,000 psi (1034 mpa) 55% 2.5 221 F RoHS compliant, UL 94V0 registered, FAR 25.853 for flammability
RPU 140 A fast curing, workhorse material that mimics the flexibility of Polypro. 4,180 psi (28 mpa) 148,000 psi (1020 mpa) 40% 0.42 177 F RoHS compliant
RPU 230 High impact, PP-like material 7,170 psi (54 mpa) 236,132 psi (1535 mpa) 56% 2.64 232 F RoHS compliant, Black only
RPU-300 Work horse ABS-like material that is easily tintable. 7,600 psi (79 mpa)) 300,000 psi (2068 mpa) 12% 0.75 195 F RoHS compliant
RPU 325-HT A strong, ABS-like material with elevated impact and high HDT 10500 psi (72 mpa) 325,000 psi (2241 mpa) 10% 1.2 346 F RoHS compliant
RPU 330 ABS-like material with elevated impact resistance and excellent elongation 8,303 psi (57 mpa) 334,159 psi (2303 mpa) 27% 1.3 170% RoHS compliant
RPU 340 A clear, UV-stable material with elevated impact resistance 10,500 psi (72 mpa) 345,000 psi (2378 mpa) 8% 1.1 203 F RoHS compliant, UV stable
RPU 380 The most rigid and high impact polyurethane available 10,010 psi (69 mpa) 386,612 psi (2665 mpa) 21.60% 2.1 190 F RoHS and REACH Compliant
RPU 420 A stiff, PC-like material that is easily tintable 10,500 psi (72 mpa) 420,000 psi (2895 mpa) 8% 0.7 171 F RoHS compliant
RPU 420-FR A stiff and rugged, FR rated material with elevated impact resistance 10,650 psi (73 mpa) 424,275 psi (2925 mpa) 24.50% 1.6 190 F RoHS and REACH Compliant, UL 94V-0 in 0.12″ (3.0 mm), FAR 25.853 for flammability
SRPU 6501-AF A very stiff, aluminum filled material used in tooling applications 3,130 psi (21 mpa) 650,000 psi (4481 mpa) 3.50% n/a 210 F RoHS compliant, Aluminum-Filled
SRPU 6502 A very stiff, high temp material for demanding applications 10,900 psi (75 mpa) 650,000 psi (4481 mpa) 2% 0.3 345 F RoHS compliant, Tan Color

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