Polyurethane machining & casting

Cost & setup

Medium · grade dependent

Material grade and density affect cost. Casting adds mold setup, which can be shared across repeated parts; machining a one-off master has a different cost structure.

Detail & surface

A suitable dense board machines cleanly, while casting can reproduce the mold surface. Bubbles, shrinkage and thin sections must be considered for the selected resin.

Strength & stiffness

Rigid, flexible and foamed PU grades behave differently. Hardness, impact performance and fixing design are specified from the actual product, not from the PU name alone.

Weight

Density and whether the part is solid, hollow or filled control weight. PU is not necessarily a lightweight foam.

Use & exposure

Heat, moisture and UV suitability depend on the formulation and protective finish.

One-off & repeated production

Machining for masters and individual forms; casting for repeated details once the mold is prepared.

Delivered finish

Prepared machined surface, molded texture, painted finish or a specified wood-effect cast surface.

How we make it

• Choose model board or casting resin and define the required properties.
• Machine the model, or prepare a mold and cast the part.
• Trim, fit attachments and complete the specified surface finish.

What can be made?

• Dense model-board masters
• Repeated decorative details
• Rigid cast components and wood-effect pieces

What affects the price?

• Material grade and density
• Mold complexity and quantity
• Casting thickness or machining time
• Surface preparation and attachments

Limitations

• Expanding PU foam and solid casting PU are not interchangeable.
• Large casting sections need a suitable resin and process plan.