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Urethane Casting - Different Methods Employed And Their Benefits

Nov 16th 2015 at 3:39 AM

With the proceeding years, almost all the fields are subjected to one or the other changes at greater speed. Manufacturing industry is no different in this subject. Advanced technologies and techniques are employed to meet the ever growing market expectations. Over the period of time, several innovative advances are also introduced in additive manufacturing process. Let us discuss a little about urethane casting and different techniques adopted for the same.

Different methods of Urethane Casting

QuantamCast: There are several cast urethane molding solutions introduced nowadays and customers are free to choose the one, which suits perfectly with their requirements. By adopting the QuantamCast method, customers can quickly manufacture tough and rigid short-run components.

CompositeCast: This method can be considered as the next level of QuantamCast. Composite sheet materials like carbon fiber, fiberglass, etc, are added into Platinum Silicon molds and as a result, tough and stiff urethane cast parts are achieved.

RotationCast: This method is ideal for manufacturing hollow parts. In this method, premium platinum silicone molds are combined with standard QuantumCast materials on a multi-axis casting platform.

Engineering Grade: This is a cost effective method generally used for non-cosmetic applications.

VolumeCast: By employing this method, many parts for one particular tool can be manufactured. The process is cost effective since no expensive hard tooling is involved.

Advantages of Urethane Casting

  1. Cost of molds is low:

Platinum silicon is used to cast molds. Molds are cast around master patterns using PolyJet, Stereolithography (SL) or CNC technologies. These molds are sufficient for 20 to 25 reproductions.

  1. Manufacturing time is less:

Soon after receiving the final CAD data, the entire cast urethane project can be shipped within 3 to 10 days.

  1. Great designing flexibility:
  • Parts intended for injection molding are created easily as urethane casts.
  • There is no need of lifters or slides since most undercuts are acceptable and draft is never a concern.
  • Thick and thin wall sections can be presented in the same part.
  • Figurines can be cast and small features are easily acceptable.
  • No sink issues.
  • Snap-fit responsive materials are available.
  • SPI/SPE A1 to D3, MT-1055-1 to MT-1055-7 and MT-11000 to MT-11040 are all available and thus cast-in surface texture is not an issue.

Urethane Casting Designing Guidelines:

Generally urethane casting production is a three step process. They are,

  • A master pattern is built by utilizing PolyJet Additive Manufacturing technologies, Stereolithography or a CNC machining center.
  • Platinum silicon mold is created.
  • Parts are casted using mostly the QuantamCast casting method.

This process of manufacturing is adopted by most of the manufacturing units because it provides greater freedom and flexibility in manufacturing different parts compared to any other manufacturing techniques.

Inspection:

Most of the parts are manufactured in ISO 9001 or AS9100 licensed facility. For standard tolerances, the first part from each and every mold is inspected. However, for premium tolerances, every manufactured part has to undergo a 6-point inspection. Generally for production projects, the entire inspection plan is geometry specific and is negotiated and considered as a part of the contract review.

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