What types of materials can be simulated using cast polyurethane?

Versatile Material Simulation Families

Cast polyurethane is exceptionally versatile, capable of simulating a wide range of commercial thermoplastics and elastomers. The resins are formulated into distinct families that mimic the mechanical properties, durometers, and even aesthetic qualities of production materials. This makes Urethane Casting an invaluable process for functional prototyping, bridge tooling, and low-volume production, allowing for accurate performance testing before investing in expensive injection molds.

Rigid and Engineering Plastic Simulants

One of the most common applications is simulating rigid engineering plastics. Formulations are available that closely mimic the strength, stiffness, and temperature resistance of materials like ABS, Polycarbonate (PC), Acrylic (PMMA), and Polypropylene (PP). There are also advanced urethane resins that can replicate the high-performance characteristics of glass-filled Nylon or even peek, providing a cost-effective way to validate designs intended for these more expensive engineering thermoplastics. This is a key service within our die castings Prototyping and die castings Engineering solutions.

Flexible and Elastomeric Simulants

Beyond rigid plastics, urethanes excel at simulating a vast spectrum of flexible and rubber-like materials. By varying the resin and hardener ratio, manufacturers can produce parts with Shore hardness values ranging from a soft, gel-like 10A to a semi-rigid 80D. This allows them to replicate the feel and performance of commodities like silicone rubber, thermoplastic polyurethanes (TPU), and TPEs. These are ideal for producing overmolded prototypes, gaskets, seals, and shock-absorbing components without the need for costly rubber injection molds.

Specialty and Composite Properties

Furthermore, specialty urethane resins offer properties that simulate other material classes. Transparent and water-clear formulations can mimic polycarbonate or acrylic for lens and light-guide applications. Other resins are designed to simulate the look and feel of cast iron or other metals for aesthetic prototypes. Additives can be incorporated to create flame-retardant, static-dissipative, or even FDA-compliant grades, further expanding the range of applications and industries served by this adaptable process. After casting, parts can undergo painting or other finishes to achieve a perfect visual match to the production intent.