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Cast Urethane Manufacturing Process
Urethane to metal bonding
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Aluminum molds are most commonly used for the manufacture of low pressure urethane parts. The molds are CNC machined from billets of aluminum.

The complexity and size of the mold is dependent on the part design and whether there are any inserts for the urethane to be molded to.

The molds will last for thousands of cycles so do not typically need replacing through the life of the part.
 
Soft molds are typically used for prototyping parts.

These molds are made using a master part, either an existing part which wants to be switched to urethane or a new rapid prototyped ABS plastic part. The master part is set in a fixture then covered in urethane to make the negative cavity.

Once the urethane is set the mold can then be used to make the prototype part. Due to the very economical cost to produce these molds for prototyping of parts their tool life is limited to 100 parts.
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