Urethane casting — also known as RTV molding and silicone molding — is a precision fabrication process engineered to produce production-grade plastic parts at low volumes. The process runs in three controlled stages: (1) Build a high-definition SLA master pattern to achieve surface finishes down to Ra 0.8 µm — capturing every texture, radius, and cosmetic detail exactly as designed; (2) Encapsulate the master in platinum-cure silicone to reproduce every geometry with zero dimensional loss; (3) Inject vacuum-grade liquid polyurethane resin — available across a full Shore A/D range — under full vacuum, eliminating air entrapment and ensuring bubble-free, void-free castings on every cycle.

Urethane casting bridges the gap between prototyping and full-scale production — delivering runs of 10 to 100 units in commercial-grade resins (ABS-like, PC-like, Nylon-like) that match the mechanical and cosmetic properties of injection-molded parts. It eliminates the capital cost and 8–12 week lead time of steel or aluminum tooling, letting you validate market fit, stress-test your design hypotheses, and supply real customers with real product — all before committing to production tooling investment.

The flexible silicone tooling unlocks geometries that traditional injection molding cannot economically achieve. Zero draft angles, complex undercuts, deep internal channels, and multi-directional features are all fully supported — no tool modifications required. If you have designed for injection molding before, standard DFM rules apply. But with urethane casting, those rules are a floor, not a ceiling: the process handles the geometry your design actually needs, not the geometry your tooling can accept. Our engineering team provides a factory-direct DFM review to maximize these design freedoms.