One-stop precision manufacturing solutions from prototype to mass production
Knowledge, tips, and support — helping you make smarter manufacturing decisions at every stage.
Tailored on-demand manufacturing solutions for diverse industries
Replace expensive tooling with fast, flexible urethane casting—ideal for validating designs and launching low-volume production without delay.
Urethane casting is a low-volume manufacturing process that uses silicone molds and polyurethane resins to produce high-quality plastic parts. It is commonly used for prototypes, functional testing, and small-batch production before moving to injection molding.
Unlike traditional tooling methods, urethane casting eliminates the need for hard steel molds, making it faster and significantly more cost-effective for early-stage production.
This process is widely used in industries that require fast iteration, tight development cycles, and flexible production quantities.
Urethane casting is a rapid manufacturing process that uses a master model and silicone molds to produce high-quality polyurethane parts for prototyping and low-volume production with excellent surface finish.
Liquid silicone is poured around the master model to create a flexible mold that accurately captures all surface features.
After the silicone fully cures, the mold is precisely cut open and the master pattern is removed without damaging the cavity.
The cast parts are fully cured inside the mold before being carefully removed to maintain shape stability and surface quality.
Final parts are trimmed, surface-finished, and inspected to ensure dimensional accuracy and consistent quality standards.
| Material Type | Characteristics | Applications |
|---|---|---|
| Rigid PU (ABS-like) | Strong, durable, good impact resistance | Enclosures, housings |
| Flexible PU (Rubber-like) | Soft, elastic, high elongation | Seals, grips, gaskets |
| Transparent PU | Optical clarity, good polish finish | Lenses, covers |
| High-temp PU | Heat resistance, stable performance | Automotive, industrial parts |
| Filled PU | Reinforced with fillers for strength | Structural components |
Rapid production to meet tight deadlines and accelerate your project.
ISO 9001 & IATF 16949 certified processes ensuring high-quality output.
Skilled engineers and operators with decades of manufacturing experience.
Reliable scheduling to ensure your orders are delivered as promised.
Tailor-made services to meet your specific project requirements.
Capable of low-volume, prototyping, and large-scale production efficiently.
Urethane casting is ideal for low-volume production and rapid prototyping without expensive tooling
While injection molding is better suited for high-volume manufacturing with lower unit cost at scale.
| Factor | Urethane Casting | Injection Molding |
|---|---|---|
| Tooling Cost | Very Low | High |
| Lead Time | Days | Weeks/Months |
| Volume | Low (10–1000+) | High (10,000+) |
| Flexibility | Very High | Low |
| Best Use | Prototypes / Bridge Production | Mass Production |
This project involved the production of a low-volume consumer electronics enclosure using urethane casting technology. The customer required high-quality prototype parts with excellent surface finish, short lead times, and appearance close to injection molded products for functional testing and market validation.
| Item | Details |
|---|---|
| Product Name | Handheld Device Housing |
| Manufacturing Process | Urethane Casting |
| Mold Type | Silicone Mold |
| Material | ABS-like Polyurethane Resin |
| Surface Finish | Matte Texture |
| Color | Black |
| Tolerance | ±0.20 mm |
| Production Volume | 50 Sets |
| Lead Time | 7 Days |
| Application | Consumer Electronics |
No expensive metal tooling required, reducing upfront development cost.
Silicone molds can be produced quickly, enabling fast part delivery.
Produces smooth, injection-molding-like finishes suitable for end-use parts.
Easy to modify and iterate designs without retooling costs.
Usually 3–7 days depending on complexity and quantity.
Typically 15–25 parts per mold before degradation.
Not for mass production, but it is ideal for prototyping and bridge manufacturing.
Injection-molding-like smooth surface with optional polishing or painting.
Depends on mold size, typically up to medium-sized components.
Caution: RapidMfg-online is full Chinese company, please don’t send any enquiry items involved export controlled by U.S. law. e.g. EAR, ITAR etc
