Javelin partners with North American leading manufacturers to provide Urethane Casting for low-mid volume production of high quality, precise, and consistent parts that can be molded from flexible, rigid or foam materials.
Our partners have developed a proprietary approach to master pattern production that is guaranteed to deliver consistency and quality in your cast components.
Learn more about the Urethane Casting service:
Urethane Casting Benefits
Fast and consistent creation of high-quality polymer parts
Rapid Part Delivery
Urethane casting gives companies a first-to-market advantage and first shots within 7-10 business days.
This allows companies to get their products on shelves long before hard-tooling for traditional injection molding could be completed.
Size & Capacity
Stratasys Direct operate the largest polymer casting enterprise in North America – both in terms of production capacity and part size capabilities.
Get the first-to-market advantage through the use of quick-turn, 3D printed master patterns and fast curing silicone molds.
Prototype & Production Parts
Urethane casting molds can yield up to 75 repeatable production components.
Before committing to a production run, we can cast a true-to-product part for testing.
Cast cosmetic housings for medical devices with healthcare-friendly materials.
How Does Urethane Casting Work?
Urethane Casting utilizes quick curing silicone molds and 3D printed master patterns.
Urethane Casting Materials
Stratasys meet industry-specific applications and unique needs with an array of Shore A and D, flexible, rigid and foam materials.
UL 94-VO and FAR 25.853 flame ratings, high temperature, clear and medical imaging materials are all available. Review materials »
Composite Casting
During the casting process, sheet materials like fiberglass, carbon fiber and Kevlar can be positioned into a mold before it is filled with material.
The resulting tough composite-reinforced cast urethane has a high flex modulus and impact strength.
Custom Casting
Developments in materials and molding methods enable customers to quickly manufacture high quality urethane castings.
Proprietary Casting Method
The proprietary casting process is a multi-step method that applies vacuum, heat and pressure to advanced formula polymers (AFP’s).
The process results in void-free, strong and stable production and pre-production components.
Molding Capacity
How many parts can you get from a single Urethane Casting mold? It depends on several factors, but a Urethane Casting mold typically yields 15 to 25 parts.
One factor that may reduce the lifespan of a mold is the geometry—sharp edges or deep undercuts tend to deteriorate more quickly.
VolumeCast—a process that utilizes hybrid tooling and proprietary casting techniques—can have an extended mold life, up to between 35 and 75 units.
What is the largest size of a part can you cast in urethane?
The maximum size for a cast urethane part is approximately 1,000 cubic inches, but large parts can be reviewed on an individual basis to determine compatibility with our casting processes.
Urethane Casting Materials
Advanced Formula Polymers (AFPs) will exceed your expectations for urethane casting and short-run production.
Utilized for clinical trials, product testing, alpha/beta builds, prototype and end-use parts, AFP offers an unmatched selection of materials to meet your applications. Materials exhibiting properties including UL94V-0 flame rating, MRI transparency and even impact resistant composite reinforced plastics are available.
Shore D Urethane (Rigid)
| Material | Description | Benefits | Applications |
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AFP3100 |
Our high Izod impact urethane for pre-production and production applications; Certified to USP Class VI requirements and RoHS 2 / REACH SVHC Compliant |
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AFP3100FR |
Our most widely used urethane for production applications with a UL 94 V-0 flammability listing at .1” thickness. RoHS 2 / REACH SVHC Compliant |
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AFP3105FR |
Used for fire retardant applications in thinner sections. Meets the requirements of FAR 28.853 Part 1, (a) (1) (i) for flammability in 0.043 inch (1.1 mm) thickness; RoHS 2 / REACH SVHC |
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Durable, high-impact strength urethane with FAR 25.853 flammability rating |
AFP3200 |
Provides a unique combination of physical properties for very tough and durable parts and assemblies. Good rigidity and stiffness due to its very high modulus. High tensile and impact strength for excellent resistance to breakage. |
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AFP3320 |
Used for very high temp applications; Heat deflection of 346F at 264 psi test; RoHS 2 / REACH SVHC Compliant |
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AFP3400 |
Used for applications that require flexibility having a low Flexural Mod. of 116,061 psi and high Izod Impact strength of 4.40ft.lbs/inch. Simulates Polypropylene. | Very good impact resistance | Prototype parts having mechanical properties close to polypropylene, with features requiring superior elongation like living hinges |
AFP3600 |
Used for applications that require a clear material; can also be tinted easily; has good heat resistance and best for smaller geometries. |
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PT8958 |
Used primarily in production applications of medium to large parts that require MRI transparency and a UL 94V0 registered flame rating. |
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RC 79D |
Used primarily in production applications of smaller parts that require MRI transparency and a UL 94V0 registered flame rating. |
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U0080DC-L |
Used for applications that require a clear material; can also be tinted easily; has good heat resistance and best for larger geometries. |
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CompositeCast with AFP3100FR |
A glass composite sheet filled version of our most widely used urethane for production applications with a UL 94 V-0 flammability listing at .1” thickness. RoHS 2 / REACH SVHC Compliant. Parts exhibit enhanced flexural and impact properties. |
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CompositeCast with PT8958 |
A glass composite sheet filled version of our MRI transparent production urethane used for medium to large parts that require MRI transparency and a UL 94V0 registered flame rating. Parts exhibit enhanced flexural and impact properties. |
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Shore A Urethane (Elastomeric)
| Material | Description | Benefits | Applications |
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| E1005AL | Extra Soft, 5 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant |
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| E1015AL | Soft, 15 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant |
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| E1025AL |
Soft, 25 Shore A Elastomer used for production parts, special effects props and medical training models; RoHs/REACH Compliant |
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| E1030AL |
Soft, 30 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs/REACH Compliant |
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| E1040AL |
Medium Soft, similar to a pencil eraser 40 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant |
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| E1050AL |
Medium Soft, similar to a Door Seal 50 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant |
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| E1060AL |
Medium Hard, 60 Shore A Elastomer used for production parts, over molding, special effects props and medical training models; RoHs Compliant |
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| E1070AB |
Medium Hard, similar to automotive tire tread 70 Shore A Elastomer used for production parts and special effects props; RoHs Compliant |
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| E1080AB | Hard, similar to Hydraulic O-Rings 80 Shore A Elastomer used for production parts and special effects props; RoHs Compliant |
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| E1090AB | Hard, similar to a squeegee 90 Shore A Elastomer used for production parts and special effects props; RoHs Compliant |
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| E1095AB | Hard, similar to a shopping cart wheel 95 Shore A Elastomer used for production parts, strain reliefs and special effects props; RoHs Compliant |
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Expanding Foam
| Material | Description | Benefits | Applications |
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| Foam-Flex V412 | Flexible, Soft, variable density foam ranging from 4-12 lbs. used in special FX, medical training and prototype seat and cushion applications. |
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| Foam-Flex V915 | Flexible, Lively, variable density foam ranging from 9-15 lbs. used in special FX, medical training and prototype seat and cushion applications. |
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| Foam-Flex V1232 | Flexible, Tough, variable density foam ranging from 12-32 lbs. used in special FX, medical training and prototype seat and cushion applications. |
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| Foam-Rigid V316 | Rigid, variable density foam ranging from 3-16 lbs. used in special FX, flotation, device/equipment insulation and prototype part applications. |
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Silicone (CompressionCast Materials)
| Material | Description | Benefits | Applications |
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| AFS15 | Soft, 15 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. | Platinum based silicone |
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| AFS30 | Soft, 30 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. | Platinum based silicone |
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| AFS40 | Medium Soft, 40 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. | Platinum based silicone |
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| AFS50 | Medium Soft, 50 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. | Platinum based silicone |
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| AFS60 | Medium hard, 60 Shore A silicone rubber used for preproduction and production parts like keypads, seals and gaskets. | Platinum based silicone |
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Molding Resources
Learn more about Molded Part Production
Canadian 3D Printing Expertise Contributes to Business Growth at Alta Injection Molding
Interested in our Urethane Casting Services?
Call us free at 1-800-298-6437 and get your questions answered