Get Precisely What You Expect With Urethane Casting ...

Nowadays, we live in a world in which science and technology have enabled great advances in all aspects of life. We have developed devices that are with us at every moment of the day, medical products that improve the success of health processes, and technology that allows us to satisfy basic needs worldwide. But how have we achieved all this?

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Today&#;s achievement involves many aspects; however, one key aspect that usually goes unnoticed is Product Design and Development. As specialists in the field, we recognize the value and impact that manufacturing skills bring to making technological advances possible.

At ARRK North America, we have extensive experience in the processes required to make products a reality. Therefore, we know Urethane Casting services are ideal for providing the best results to the market. Stay with us and learn how we make our customers&#; ideas possible through excellent quality processes, care, design, and engineering resources.

Understanding ARRK&#;s Urethane Casting Services

With over 70 years of experience becoming Prototyping and Low-volume Production experts, ARRK North America has specialized in Urethane Casting, one of the most widely used processes in the manufacturing industry due to the great benefits obtained. Let&#;s take a closer look at how this process works.

How it works

1. Whether the customer has a rough sketch or a defined digital file of the component to be developed, we create a master model with our excellent 3D Printing methods.
2. The master model is placed in a container where liquid silicone is poured, creating the mold of the part. This can also be done by adding a vacuum, becoming a slightly different process called Vacuum Casting.
3. Afterward, the selected liquid resin is poured into the silicone mold and allowed to cure until it&#;s ready.
4. The component is removed from the mold.
5. Due to its flexibility, the silicone mold allows the creation of components with complex geometry and can be reused 10 to 15 times without losing its properties.

Materials selection

• Rigid
  Rigid urethane materials are selected for components that must be strong and durable. For example, they are used for automotive trims, casings, headlights, hand tools, and more. At ARRK, we use ABS, clear, and UL94V0-rated urethane, among others.
  

• Elastomeric
  Elastomeric urethane materials are soft and flexible, with rubber-like properties. At ARRK, we have urethane castings from 20 Shore A to 90 Shore A.
  

• Functionality & Aesthetics
  With ARKK&#;s Urethane Casting services know-how, companies get functional and visually appealing components, with excellent surface finishes and remarkable details.
  
  
  Each part can be painted after the process, but it is recommended&#;for greater precision and detail&#;to add color to the resins during the process and pour them into the silicone mold. A wide variety of shades are available, and we can also match pigments for Pantones and RAL classifications or adapt to customers&#; samples.

Urethane Cast Results & Applications

As we can see, the Urethane Casting process offers many possibilities and a wide variety of results, so companies get the quality they deserve. In addition, it is a method that reduces lead times while helping to lower the initial investment cost since the silicone molds are created at high speeds, and the material is cost-efficient and very effective.

Although it can be used for end-use parts, it is mainly used for prototyping because the number of parts required per batch is small. However, this makes it possible to ensure that each piece meets the objectives and, if necessary, it is possible to make design changes without wasting a lot of time or money.

For all these reasons, UC has become a great ally of several industries, such as the following:

• Consumer Electronics

We have developed components such as home appliances, white goods, devices, TVs, and more.

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• Robotics

We are skillful developers with all the necessary knowledge for creating agriculture and commercial robots, drones, etc.

• Medical Devices

As certified experts in the manufacturing field, we are able to design laser devices, medical machines, and more.

At ARRK North America, we have worked with all industries, creating prototypes that look, feel, and act like end products, thanks to our Casting expertise. We like to provide solutions that will enable manufacturers to make their ideas a tangible reality.

We are not only suppliers, we are partners that will work with you in all stages of the process, providing insights, solutions, and the best options so that your product meets all your expectations.

If you&#;re still in the first steps of the process but want to have everything ready for the manufacturing stage, don&#;t hesitate to contact us and let us know what you expect. Get a free quote and get to know our customer service team; we will provide you with all the information you need to feel comfortable trusting part of your production in the hands of the experts. Start the ARRK journey and get precisely what you&#;re looking for!

The Basics Of Urethane Casting

Urethane casting provides end-use, rigid, flexible, and rubber parts with production-level quality. The urethane casting process uses a 3D-printed master pattern to create a silicone mold that delivers high-quality, short-run parts as an economical alternative to low-volume injection molding.

How Urethane Casting Works

Urethane casting is similar to injection molding in that it requires a tool with a cavity in the shape of the final part. The major difference is that urethane casting uses a "soft" mold made of silicone whereas injection molding using a "hard" metal mold that has been CNC machined. The drawback to urethane casting, then, is that the mold wears out more quickly. However, it is vastly more cost-efficient for low-volume and prototype plastic parts that require production-level quality and surface finishes.

The urethane casting process has 3 major steps:

1. The Master Pattern: In step one, a master pattern of the final part is made using an additive manufacturing process. Polyjet 3D or stereolithography (SLA) 3D printing processes are most often used due to their ability to produce high-resolution and naturally smooth finish parts. The master pattern is typically hand-finished to achieve optimal surface detail before the creation of the mold tool.
2. Molding: In step two, the 3D printed master pattern is encased in liquid silicone that cures around the pattern, with the silicone encapsulating all the features of the printed parts. When the mold cures, it is cut into distinct halves and the master pattern or 3D printed part, is removed. This leaves an internal cavity perfectly shaped like the part.
3. Pouring: In the final step of the urethane casting process, liquid urethane or silicone is poured into the silicone mold, and the mold is then placed in a chamber to help remove air bubbles in the liquid material. For opaque parts, the chamber is typically pressurized. For clear parts, the chamber typically pulls a vacuum to mitigate any bubbles and increase clarity. Once cured, the silicone halves are separated and the newly formed part is removed. This process is repeated until the desired quantity is achieved.

Benefits Of Urethane Casting

Urethane casting has a low-cost and quick turnaround for high-quality plastic parts compared to injection molding or 3D printing. Where injection molding requires an expensive upfront investment for the machining of the mold, the silicone mold required for urethane casting is inexpensive and easy to produce. Additionally, while most 3D printing processes require extensive post-processing to get to a near-finished state, urethane cast parts come out of the mold ready to go. Urethane casting is an excellent choice for creating high-quality prototypes or low-volume production of rigid, flexible, clear, colored, or rubber-like plastic parts.