Urethane Casting Services
Production-quality parts without the tooling investment
Vacuum Casting & Low-Volume Polyurethane Production
JLYPT specialises in vacuum casting — a low-volume manufacturing process that bridges rapid prototyping and traditional injection moulding. Using polyurethane resins and precision silicone moulds, we deliver production-quality parts in quantities of 10 to 500 units without the significant tooling investment of injection moulding.
Our vacuum casting process creates silicone moulds from 3D-printed masters or patterns, then pours polyurethane resin formulations that replicate the properties of ABS, polypropylene, rubbers or specialty materials. The vacuum-assisted process eliminates air bubbles and porosity, producing parts with exceptional surface finish, fine detail, dimensional accuracy and consistent quality.
Ideal for bridge production, design validation, product launches, limited-edition runs and specialised applications, vacuum casting delivers parts in 2-4 weeks. We offer over-moulding, insert moulding, colour matching and custom formulations without the lead time and expense of traditional CNC machining or surface finishing tooling.
Silicone Moulds from 3D-Printed Masters
Precision silicone moulds created from your CAD files or physical samples. High-resolution 3D-printed masters are reproduced in high-durability silicone — each mould produces 20-25 high-quality castings, carefully designed to maximise detail reproduction.
Production-Grade Material Options
ABS-like rigid plastics, PP-like thermoplastics, flexible elastomers with Shore A hardness, durable rubbers or transparent polyurethane. Engineered to match or exceed injection-moulded properties — Shore A 40 to Shore D 85.
Vacuum Casting for Superior Quality
Polyurethane resin is vacuum-poured into silicone moulds, eliminating bubbles and porosity. Typical tolerance ±0.1 mm, flawless surface finish and complete mould fill — parts emerge with zero voids and exceptional detail.
Insert Moulding & Over-Moulding
Metal inserts (threaded, bushings, heat-set) directly cast into parts. Over-moulding combines different materials or hardnesses in a single part — perfect for functional components with integrated fasteners.
Colour Matching & Custom Finishes
Thousands of colours available — match Pantone numbers, brand colours or existing samples. Painting, polishing, media blasting and special surface treatments available post-casting.
Rapid Delivery, No Tooling Costs
Injection mould tooling costs $5 000-$50 000+. Vacuum casting moulds cost $500-$2 000 and are ready in 1-2 weeks. Production runs of 10-500 units deliver in 2-4 weeks. No tool changes for design iterations.
Vacuum Casting Material & Production Specifications
| Material Type | Shore Hardness | Colour Options | Quantity Range | Lead Time |
|---|---|---|---|---|
| ABS-Like Rigid Plastic | Shore D 70-85 | All colours | 10-500 units | 2-4 weeks |
| Polypropylene (PP)-Like | Shore D 65-80 | Standard + custom | 10-500 units | 2-4 weeks |
| Flexible Elastomer | Shore A 40-90 | Limited selection | 10-300 units | 2-4 weeks |
| Rubber-Like TPE | Shore A 60-85 | Black, natural colours | 10-250 units | 2-4 weeks |
| Transparent Polyurethane | Shore D 75-85 | Clear, tinted | 10-200 units | 3-4 weeks |
| Custom Formulations | Variable | Custom | 10-500 units | 3-5 weeks |
Urethane Casting Advantages
Zero Tooling Investment
Silicone moulds cost 90% less than injection moulding dies. Produce high-quality parts without $5 000-$50 000+ tooling — ideal for startups, limited runs and design validation.
Production-Quality Surface Finish
Ra 0.8-3.2 µm finish with sharp detail and dimensional accuracy comparable to injection moulded parts. No visible mould marks or parting lines.
Flexible Batch Quantities
10-500 units with no minimum. Scale up or down without tooling changes or inventory waste — perfect for bridge production and custom orders.
Rapid Delivery (2-4 Weeks)
From CAD to finished parts in 2-4 weeks. Moulds are created quickly and casting begins immediately. Significantly faster than injection moulding.
Extensive Material & Colour Variety
Rigid plastics, elastomers, transparent resins and specialty materials. Any Pantone colour. Shore A 40 to Shore D 85 hardness.
Cost-Effective for Small Batches
Per-unit costs typically 40-60% lower than injection moulding for 10-500 unit batches — no tooling amortisation overhead.
Vacuum Casting Production Process
Master Pattern Creation
We receive your CAD files or physical samples. From CAD we 3D-print a high-resolution resin master; existing patterns are evaluated for mould creation. Masters are refined for optimal mould quality.
Silicone Mould Fabrication
Master is boxed with a mould frame. High-durability silicone is mixed, degassed and poured around the master. After curing (~24 hours), the mould is removed, inspected and cleaned thoroughly.
Material Prep & Vacuum Degassing
Selected polyurethane resin is mixed to spec, vacuum-degassed to remove bubbles. Pigments, additives or special formulations are incorporated. Material is maintained at optimal temperature and viscosity.
Vacuum Casting & Mould Filling
Resin is vacuum-poured into the silicone mould — vacuum pulls resin into all cavities and ensures complete fill. Parts cure 4-8 hours depending on formulation.
Demoulding, Finishing & QC
Cured parts are removed, excess material trimmed and parts inspected for dimensional accuracy, surface quality and defects. Optional painting, polishing or media blasting. Final QC before packaging.
When Urethane Casting Is the Right Call
Urethane (vacuum) casting fills the gap between 3D printing and injection moulding. You make one master — usually CNC-machined or 3D-printed — pour a silicone mould around it, then cast polyurethane copies under vacuum. The silicone mould costs a fraction of hard steel tooling and is ready in days, so you get injection-quality look and feel at low volume without the tooling bill.
The sweet spot is roughly 20 to a few hundred parts. Below that, printing each part is usually cheaper; above it, injection moulding’s per-part cost wins. For the full quantity-based decision across CNC, printing and casting, see our rapid prototyping guide.
| Factor | 3D printing | Urethane casting | Injection moulding |
|---|---|---|---|
| Sweet-spot quantity | 1–10 | 20–500 | 1,000+ |
| Tooling | None | Silicone mould (days) | Steel tool (weeks) |
| Cost per part | Flat, higher | Low once moulded | Lowest at volume |
| Finish & consistency | Layer lines | Excellent (mould finish) | Production |
| Lead time (batch) | Hours–days | ~1 week | Weeks |
Materials — Mimicking Production Plastics
Polyurethane casting resins are formulated to imitate common production plastics, so a cast prototype behaves close to the real thing for testing and presentation.
- Rigid ABS/PC-like resins for housings and structural parts.
- Flexible PP-like resins for living hinges and snap fits.
- Rubber-like elastomers across a range of Shore hardnesses for seals, grips and overmoulds.
- Clear resins for lenses and light pipes; colour matched or painted finishes.
- Glass-filled and heat-resistant grades for tougher functional testing.
Getting a Great Cast Part
The cast is only as good as the master, so we start there. A CNC-machined or high-resolution printed master gives crisp detail that the silicone faithfully reproduces across every copy. We finish the master, build the mould, and cast a consistent batch — often reusing a master we already made for you during machining or printing.
Need functional parts in the real production material instead? That is a job for CNC machining. Comparing routes? Our CNC vs 3D printing guide covers the trade-offs.
Frequently Asked Questions
How many castings can a silicone mould produce?
Typically 20-25 castings before detail softens. With care and mould-release agents some moulds reach 30. For runs larger than 25, we create multiple moulds — still far cheaper than injection tooling.
How accurate are vacuum-cast parts vs injection moulding?
±0.1-0.15 mm on most features — comparable to injection moulding. Fine detail down to 0.5 mm. Surface finish Ra 0.8-1.6 µm. Minimum recommended wall thickness 1-2 mm for optimal edge definition.
How do polyurethane properties compare to injection-moulded plastics?
Closely mimic ABS, PP and rubber hardness and flex modulus. Tensile strength 95-98% of injection-moulded equivalents. Shrinkage ~0.5%. For non-structural applications parts are functionally identical; for high-stress we recommend mechanical testing.
What are typical lead times?
Standard 2-4 weeks: 1-2 weeks mould creation + 1-2 weeks casting and finishing. Rush mould service 5-7 days and expedited casting available for premium fees.
Can you colour-match existing products or Pantone?
Yes. Provide a physical sample, Pantone number or design spec — we formulate polyurethane in virtually any colour. Metallic, translucent and specialty finishes available with slight lead-time extension. Colour samples can be approved before full production.
What are the size and complexity limits?
Parts up to 300 × 200 × 150 mm typical; larger sizes possible with custom mould design. Handles undercuts, 1 mm thin walls, inserts and detailed features. Sections under 0.5 mm may show detail softening.
Guides & Resources
In-depth engineering guides from our team to help you specify and buy with confidence.
Related Services
Rapid 3D Printing Services
Additive manufacturing for master pattern creation and complementary prototyping.
Learn More →CNC Machining Services
Precision CNC milling and turning for high-volume or final production parts.
Learn More →Surface Finishing Services
Post-casting painting, polishing, plating and specialised finishing.
Learn More →Start Your Vacuum Casting Project Today
Send your CAD files or samples — our team will prepare a detailed quote with mould timelines and production schedule. Zero tooling investment. Production-quality parts in 2-4 weeks.
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