Can urethane casting simulate multiple materials or dual-durometer assemblies?

Simulating Multi-Material Assemblies with Urethane Casting

Yes, absolutely. Urethane Casting is exceptionally capable of simulating multi-material or dual-durometer assemblies in a single, integrated prototype. This is a key advantage for functional testing and user experience validation.

The Overmolding Process in a Silicone Mold

This is achieved through a multi-stage casting process within the same flexible silicone mold. First, a rigid urethane resin is poured to form the substrate or core of the part. After this initial material partially or fully cures, a second, softer urethane resin with a different durometer (e.g., a flexible, rubber-like material) is introduced into the same mold to form the overmolded features. The chemical bond formed between the layers creates a seamless, monolithic prototype that accurately mimics a production overmolded part.

Benefits for Design Validation

This technique allows designers to prototype complex items such as tool grips with soft-touch surfaces, buttons with rigid cores and flexible seals, or consumer electronics cases with integrated gaskets. It provides critical insight into the material interaction, ergonomics, and functionality of the design long before committing to expensive multi-shot injection molding tooling. This process is a cornerstone of our integrated One-Stop Service for Prototyping, enabling full product validation.