About Vacuum Casting/Urethane Casting:
Urethane Casting Process
Urethane casting (vacuum casting) transforms liquid resins into high-fidelity plastic or rubber parts using silicone molds—perfect for prototypes or low-volume batches. Our ISO-certified process delivers ±0.10mm tolerances and production-ready finishes in just 5 days.
Digital-First Master Patterns
Upload your CAD to our intuitive dashboard for online DFM feedback—no design delays. We craft master patterns via:
- ⇒ Precision 3D Printing (24 hr): SLA/DLP for complex geometries (±0.05mm).
- ⇒ CNC Machining (48 hr): Ideal for ultra-tight tolerances (±0.020mm).
- ⇒ Your choice: speed (3D) or precision (CNC). We optimize drafts, wall thickness, and undercuts upfront.
Silicone Mold Fabrication (48 Hours)
Liquid platinum silicone is poured over your master pattern in a vacuum chamber, eliminating bubbles for flawless detail capture. Our molds:
- ⇒ Achieve 30+ shots (vs. industry-standard 20).
- ⇒ Support textures: SPI gloss, VDI grit, custom EDM.
- ⇒ Cure 2× faster via controlled thermal acceleration.
Vacuum Casting & Intelligent Finishing
Under vacuum, we inject engineering-grade urethanes (ABS-like, PC-like, TPU) into molds. After curing:
- ⇒ Zero-Defect Guarantee: 100% inspection via CMM & visual QA.
- ⇒ Scalable Output: Produce 15–20 parts/mold/day (50% faster than competitors).
- ⇒ Smart Post-Processing: CNC trimming, painting, or pad printing—track progress in real-time via your dashboard.
Urethane Casting: From Prototype to Market
Accelerate Your Product Journey
Accelerate your product journey with end-to-end vacuum casting solutions engineered for speed-to-market—no tooling investment required.
Concept Validation (1–5 Days)
➤ Turn napkin sketches into tangible proofs faster than 3D printing
➤ Online DFM Feedback: AI-powered analysis within 1 hour of CAD upload
➤ Same-Day Master Patterns: SLA/DLP printed at ±0.05mm accuracy
➤ Zero Tooling Costs: Ideal for verifying form, ergonomics, and aesthetics
Functional Prototyping (5 Days | 1–50 Units)
➤ Test like it’s production — without production delays
➤ 48-Hour Silicone Molds: Platinum-cure for 30+ high-fidelity shots
➤ True Material Mimicry: ABS-like, PC-like, or TPU resins with >95% property match
➤ Critical Testing Ready: Validate snap-fits, seals, and impact resistance
Bridge Production (5–7 Days | 50–500 Units)
➤ Launch products before injection molds are cut
➤ Batch Consistency: Automated vacuum casting for ±0.10mm tolerances
➤ Scalable Capacity: Produce 200+ parts/week—no volume surcharges
➤ End-Use Compliance: Medical (USP VI), flame-retardant (UL94 V-0), optical clarity
Low-Volume Manufacturing (Ongoing | 500+ Units/Yr)
➤ Your agile alternative to mass production
➤ Perpetual Mold Life: Mold refurbishment for 100+ additional shots
➤ Cost-Optimized Runs: 40% lower per-part cost vs. competitors at 100-unit batches
➤ Just-in-Time Delivery: Kanban-supported replenishment
Our Solution - One partner. No tooling. No minimums. No delays.
Urethane Casting Services and Capabilities
Production-ready urethane cast parts in just 5 days—accelerating your product development from functional prototyping to low-volume end-use production (10-500+ units). Operating from ISO 9001:2015 and ISO 13485:2016 certified facilities, we guarantee cost efficiency and on-time delivery with industry-leading speed: 48-hour mold fabrication and same-day resin casting under vacuum ensure ±0.10mm tolerances while slashing traditional lead times by 40%. Choose from the broadest range of engineering-grade polyurethanes—including ABS-like, PC-like, TPU, FDA-compliant, and medical-grade resins—with custom finishes for automotive, aerospace, medical, and consumer applications. Zero minimum order quantities and real-time production tracking provide unmatched flexibility, making us the smart alternative to injection molding for batches under 500 parts.
Technical Capabilities & Specifications
| Parameter | Specification | Detail |
|---|---|---|
| Tolerance | ±0.15mm (local), ±0.10mm (small holes) | ISO-2768-C compliant |
| Max Part Size | 2.3 × 1.3 × 0.6 meters | Accommodates large components |
| Daily Capacity | 200 pieces | Scalable for batch production |
| Surface Roughness | SPI A1 (0.012–0.025μm Ra) to VDI textures | Glossy, matte, or technical finishes |
| Lead Time | 5 days (simple parts) | Includes mold creation, casting, finishing |
3D Printing vs. Vacuum Casting vs. Injection Molding
| Parameter | 3D Printing | Vacuum Casting | Injection Molding |
|---|---|---|---|
| Production Volume | 1–100 units | 10–200 units | 1,000+ units |
| Tooling Cost | $0 | $500–$3,000 | $5,000–$50,000+ |
| Per-Unit Cost | High | Moderate | Low (at scale) |
| Lead Time | 1–3 days | 5–15 days | 4–12 weeks |
| Material Options | PLA, ABS, resins, nylon | Polyurethane (ABS/PC-like) | ABS, PP, PC, elastomers, etc. |
| Tolerance & Precision | ±0.1–0.5mm | ±0.15mm | ±0.1–0.2mm |
| Surface Finish | Layered, rough | Near-production quality | Production-grade finish |
| Design Flexibility | High (complex geometries) | Moderate (some undercuts) | Restricted (draft angles needed) |
| Mold/Part Durability | N/A (direct print) | 15–50 uses | 100,000+ cycles |
| Material Waste | Moderate | Low | Negligible |
| Best For | Prototypes, jigs, 1-offs | Functional prototypes, bridge runs | Mass production |
| Material (Polyurethane) | Hardness, Shore D | Density (g/cc) | Color Availability | Tensile Strength (psi) | Elongation (%) |
|---|---|---|---|---|---|
| ABS-like | 80 | 1.3 | Black, Natural, Color-Match | 6,117 | 21 |
| General Purpose | 78 | 1.15 | Black, Natural, Color-Match | 7,000 | 12 |
| General Purpose | 78 | 1.09 | Colorless/Clear | 4,230 | 155 |
| Glass-Filled Nylon-like | 85 | 1.13 | Black, Natural, Color-Match | 10,010 | 21.6 |
| Polypropylene-like | 70 | 1.13 | Black, Natural, Color-Match | 3,310 | 28.3 |
| Polycarbonate-like | 84 | 1.2 | Black, Natural, Color-Match | 10,060 | 10.5 |
| Rigid Clear Polyurethane | 80 | 1.25 | Colorless | 12,000 | 40 |
| Rubber-like | 30 | 1.036 | Black, Natural, Color-Match | 1,050 | 1300 |
| Rubber-like | 40 | 1.056 | Black, Natural, Color-Match | 940 | 800 |
| Rubber-like | 50 | 1.088 | Black, Natural, Color-Match | 1,020 | 650 |
| Rubber-like | 60 | 1.07 | Black, Natural, Color-Match | 1,260 | 625 |
| Rubber-like | 70 | 1.07 | Black, Natural, Color-Match | 1,803 | 1147 |
| Rubber-like | 80 | 1.1 | Black, Natural, Color-Match | 3,720 | 650 |
| Rubber-like | 90 | 1.094 | Black, Natural, Color-Match | 7,420 | 670 |
| Rubber-like | 45 | 1.06 | Colorless/Clear | 390 | 300 |
| Rubber-like | 65 | 1.02 | Colorless/Clear | 753 | 200 |
| Rubber-like | 70 | 1.02 | Colorless/Clear | 1,370 | 300 |
| Rubber-like | 90 | 1.03 | Colorless/Clear | 4,000 | 180 |
All values shown above are approximate only
Urethane Casting Applications
Automotive & Mobility
- Interior Systems: UV-resistant dashboards, tactile buttons, vent grilles
- Underhood: Heat-shielded sensor housings (180°C EP-430 resin)
- Validation: Overmolded gaskets, snap-fit assemblies for crash testing
Medical & Life Sciences
- Biocompatible Devices: USP Class VI surgical tools, fluid connectors
- Diagnostic Gear: Fog-resistant transparent housings for imaging
- Wearables: Skin-safe wearable trial batches (50 units in 7 days)
Industrial & Robotics
- Robotics: Oil-resistant gripper pads, impact-absorbing joints
- Machinery: Chemical-resistant guards, custom tooling fixtures
- Energy: Dielectric bushings, arc-resistant switch covers
Electronics & IoT
- Enclosures: IP67-rated cases with living hinges, snap fits
- Connectors: Overmolded USB ports, heat-free insert molding
- Consumer Tech: Silky-touch grips, optically clear display covers
Aerospace & Defense
- Cabin Interiors: Flame-retardant (UL94 V-0) seat components, ducting
- Avionics: EMI/RFI-shielded enclosures, vibration-dampened mounts
- Drones: Lightweight propeller housings (0.8g/cm³ foamed resins)
Get a Project Review | Contact Our Engineering Team | Request a Callback
Zero-Compromise Quality Assurance
Certified Precision for Critical Parts
As an ISO 9001:2015 certified provider, we enforce rigorous quality protocols across our global manufacturer network. Every vacuum-cast part undergoes triple-validated inspections – blending speed with uncompromised accuracy.
|
Dimensional & Geometric Verification |
Metrology Suite: In-house CMM (±0.003mm), optical comparators, and laser scanners Real-Time Reporting: Deviation maps synced to your dashboard Critical Checks: • Tolerances to ±0.10mm (50% tighter than industry average) • Wall thickness uniformity, hole positions, and GD&T alignment |
|
Surface & Aesthetic Integrity |
Flaw Screening: Bubbles, sink marks, and flow lines under UV/white light Defect Detection: 10× magnified visual inspections + SPI/VDI roughness testers Standards Compliance: • SPI A1–VDI 3400 finishes (glossy/matte/textured) • Pantone color matching (ΔE < 1.5) |
|
Material & Performance Validation |
Functional Validation: Snap-fit, leak, and impact tests for end-use readiness Resin Certification: Batch-tested tensile strength, hardness (Shore A/D), and heat deflection Compliance Testing: • Biocompatibility (USP VI/ISO 10993) for medical parts • Flame Resistance (UL94 V-0) for automotive/aerospace • Adhesion Cross-Cut Testing (ASTM D3359) for coatings/platings |
100% Quality Guarantee:
"We re-cast or refund any part failing inspection – with expedited 3-day turnaround."
“No shortcuts. No surprises. Just production-grade parts – on time, every time.”
Why Choose Clarwe for Urethane Casting Services?
Partner with us for production-ready parts in just 5 days—combining the tight tolerances (±0.10mm) and material
versatility of urethane casting with the agility only an on-demand manufacturing leader delivers. Unlike platforms that
outsource to unvetted workshops, our ISO 9001:2015 and ISO 13485-certified manufacturer network guarantees consistent
quality at any scale—from 1 prototype to 500+ end-use parts—with no minimum order sizes. We simplify complexity: submit
your CAD via our intuitive dashboard for online DFM feedback, real-time order tracking, and seamless scaling, all
backed by a 100% quality guarantee that includes first-article inspection reports and material certifications.
While competitors limit flexibility, we offer industry-leading speed (48-hour mold fabrication, same-day casting) and
50+ engineering-grade resins—from medical-compliant to aerospace-grade urethanes. Our platform eliminates friction:
manage projects 24/7 with batch replication, automated quotes, and dedicated engineer support. Choose confidence over
compromise: we absorb the risk with on-time delivery, zero tooling investments, and ISO-certified precision that turns
concepts into market-ready parts faster.
Clarwe's Platform Advantage
Our integrated dashboard delivers end-to-end project command—streamlining workflows while ensuring transparency at every stage. Experience seamless coordination from initial request to final delivery, all within a single secure interface.
Submit & Configure
| RFQ Initiation |
Upload CAD files (STEP, IGES, SLDPRT) and drawings Specify requirements: materials, tolerances, finishes, inspection protocols Request custom documentation: material certs, CMM reports, customs forms |
| Real-Time Quoting |
Receive online DFM analysis with cost drivers flagged Adjust configurations (e.g., material substitutions) to optimize pricing |
Order Execution & Oversight
| Document Management |
Submit customs declarations, commercial invoices, and HS codes Upload purchase orders or approve terms for payment Access digital invoices with tax/line-item breakdowns |
| Production Intelligence |
Track progress and updates View Shop floor photos/videos Access Inspection reports, quality documents and Material certifications Monitor shipping status with carrier integrations |
Proactive Collaboration & Support
| Engineer Engagement |
Send technical queries and status enquiries to our engineers via encrypted chat Receive resolution timelines for technical queries |
| Quality Assurance Hub |
Access pre-shipment documentation: First-article inspection reports, dimensional reports and quality
documents Approve/reject deliverables via annotated media |
| Post-Delivery Excellence |
Initiate reorders with one-click cloning Log support tickets for non-conformances Archive project history (drawings, certs, comms) for audits |
Industries specialized
Aerospace
Automotive
Consumer Products
Medical
Frequently Asked Questions about Urethane Casting
Vacuum casting (urethane casting) is a low-volume manufacturing process that uses silicone molds to produce high-fidelity plastic or rubber parts (typically 10–500+ units). It’s ideal when you need:
- Production-like material properties (ABS, PC, TPU, or medical-grade resins) without injection molding tooling costs
- 5-day lead times for functional prototypes, bridge production, or end-use parts
- Complex geometries with ±0.10mm tolerances and SPI/VDI surface finishes
We streamline workflows via:
- 48-hour silicone mold fabrication (vs. 3–5 days elsewhere) using platinum-cure silicones for 30+ shots
- Same-day resin casting under ISO-certified vacuum chambers to eliminate bubbles
- Real-time dashboard tracking for mold curing, casting, and shipping milestones
Beyond standard ABS/PC-like resins, we provide:
- 50+ engineering-grade polyurethanes, including: - Aerospace EP-430 (180°C heat resistance) for underhood automotive parts
- Custom material blending for flame-retardant (UL94 V-0), static-dissipative, or foamed-lightweight properties
- FDA-compliant/medical-grade resins (USP Class VI) for surgical tools or food-contact items
- Optical-clear PMMA (92% light transmission) for lenses or displays
Yes – with no minimum order requirements:
- 1–50 units: Functional prototypes for fit/performance testing
- 50–500 units: Bridge production for market launches or pre-series validation
- 500+ units/year: Low-volume manufacturing with mold refurbishment (100+ additional shots per mold)
Our ISO 9001:2015 & ISO 13485-certified network guarantees:
- First-article inspections with CMM reports for ±0.10mm accuracy
- Material certifications for mechanical, thermal, or biocompliance properties
- Post-processing options: UV printing, vacuum plating, EDM textures, or Pantone-matched colors
Our services are critical for industries where precision, compliance, and speed are non-negotiable, including:
- Medical & Healthcare: Biocompatible surgical tools and device housings.
- Automotive: Interior trim, functional prototypes, and ducting.
- Aerospace & Defense: Lightweight, flame-retardant components.
- Consumer Electronics: Enclosures, buttons, and connectors for market testing.
Here’s a simplified breakdown:
| Factor | 3D Printing | Vacuum Casting (Clarwe) | Injection Molding |
|---|---|---|---|
| Tooling Cost | $0 | $350–$1,500 | $5,000–$50,000+ |
| Ideal Volume | 1–20 | 1–500+ | 1,000+ |
| Lead Time | 1–3 days | 5 days | 4–12 weeks |
| Surface Finish | Layer lines (needs post-work) | Near-production (SPI A1-VDI) | Production-grade |
| Per-Part Cost | $$$ (1–10 units) | $$ (20–100 units) | $ (1,000+ units) |
Our dashboard enables:
DFM feedback within 1 hour of CAD upload (vs. 24+ hours manually).
Live production tracking from mold curing to resin casting.
Batch replication at 30% reduced cost for reorders.
No more opaque processes – unlike competitors.
Urethane casting (or vacuum casting) is a process for producing high-quality, functional plastic and rubber parts in low volumes. It involves creating a silicone mold from a 3D-printed or CNC-machined master pattern. Liquid polyurethane resin is then injected into this mold under a vacuum to eliminate air bubbles, resulting in parts with excellent detail, tight tolerances (±0.10mm), and production-like material properties. It's the ideal solution for 50-500+ units, bridging the gap between 3D printing and expensive injection molding.
The choice depends on your volume, budget, and timeline:
- Choose 3D Printing for 1-10 prototypes where speed for a single part is critical and material properties are less important.
- Choose Urethane Casting for 1-500+ parts where you need production-grade materials, finishes, and tolerances without the high cost and lead time of injection molding tooling. It's perfect for functional testing, market launches, and bridge production.
- Choose Injection Molding for true mass production of 1,000+ parts, where the lower per-part cost justifies the high initial tooling investment and longer lead time.
Our standard lead time is just 5–7 days for most orders, significantly faster than the industry average. We achieve this through our 48-hour mold fabrication process and streamlined production workflow. Unlike many competitors, we don't outsource, which gives us complete control over our schedule and ensures your project stays on track.
No. We offer true on-demand manufacturing with zero MOQs. You can order a single prototype for validation or 500+ parts for low-volume production. We never charge batch premiums for small orders, making us the most flexible option compared to other platforms.
We offer an industry-leading selection of 50+ engineering-grade polyurethane resins to mimic a wide range of commercial thermoplastics and elastomers, including:
- ABS-like & PC-like: For rigid, structural components.
- TPU-like & Rubber-like: For flexible, shock-absorbing parts.
- PP-like: For living hinges and chemical resistance.
- High-Temp (up to 180°C): For under-hood automotive or aerospace applications.
- Optically Clear: For lenses and light pipes.
- Medical & FDA-Compliant: For skin-contact or food-safe products.
Quality is engineered into every step. As an ISO 9001:2015 certified provider, we employ a rigorous multi-stage QC process:
- Dimensional Inspection: Every first article is verified with CMM and precision gauges to ensure ±0.10mm tolerances.
- Visual & Surface Inspection: Parts are checked for defects against finish standards and Pantone color matches.
- Material Certification: Resins are batch-tested, and certifications are provided upon request.
This commitment to quality guarantees that your parts are not just prototypes but production-ready.
Our process is designed for simplicity and transparency:
- Upload Your CAD File to our intuitive online platform.
- Receive an Online Quote and automated DFM feedback within hours—not days.
- Review & Approve your order while tracking every milestone through your personal dashboard.
- Production & Shipping: We manufacture your parts and provide seamless logistics to your door.
Your intellectual property is completely secure. We operate under strict NDA agreements ensuring all your design data and project details remain confidential. Our secure, ISO-certified manufacturing network is vetted for compliance and data security.