Urethane Casting

Low Volumes with Production-Level Quality

How Does Urethane Casting Work?

Urethane casting provides end-use, rigid or flexible plastic parts with production-level quality. Built without expensive and time-consuming hard tooling, our urethane casting process uses a 3D printed master pattern and silicone molds to deliver high-quality, short-run parts up to 30” long. The finished dimensions of urethane cast parts depends on the accuracy of the master model, part geometry and casting material. In general, a shrinkage rate of + 0.15% is expected.

Urethane Casting

Urethane Casting Featured Resources

Three Benefits of Urethane Casting

Three Benefits of Urethane Casting

Whether you’re a Fortune 500 company or a start-up looking to beat your competitor to market, striking the right balance between high-quality, end-use parts and production lead-time can be a headache.

Urethane Casting Applications

Low-Volume Production

Urethane cast parts are perfect for low-quantity production — when volumes do not justify investment in injection mold tooling — as well as for first run production parts, which can be completed weeks before production tooling is ready.

Advanced Prototyping

The urethane casting process and relatively inexpensive tooling involved makes it easy and economical to make any necessary design changes. Additionally, different materials can be used with the same mold, making it possible to test designs with a variety of materials.

Market Testing

End-user functionality and a high-quality finish makes urethane cast parts ideal for consumer testing, user evaluation and concept models. Using the cast urethane process means that changes can be incorporated quickly for either further testing or market launch.

Urethane Casting Advantages


Polyurethane cast materials are available in rigid or flexible end-use plastics. Urethane cast parts are generally as tough or tougher than injection molded pieces, and are significantly stronger than 3D printed counterparts.


Our casting process is optimal for low-volume production for quantities of one to several hundred. On average, a silicone mold can accurately cast about 20-25 parts. The maximum quantity varies based on part design and material cast.

Material Selection

We offer a wide range of rigid and flexible urethane cast materials, from very soft and flexible (Shore A) to extremely rigid and impact resistant (Shore D). Parts are cast in a color that is blended to your specifications.

Color Matching & Finishes

The urethane casting process is capable of reproducing small details. Little to no finishing is required, because the desired textures and finish levels are applied to the master pattern.

Rapid Turnaround

Urethane cast parts are shipped within 15 business days, depending on order specifications and volume. By contrast, injection molded parts can take months to build.

Urethane Casting Materials


  • Polyurethane (PU)
  • Silicone

Urethane Casting Finishes


Parts are built with a smooth, high-quality surface finish and your choice of color.


Xometry can provide additional processing, including custom texture and insert installation, to meet your needs.

Urethane Casting Design Guide

Urethane Casting Design Guide

Urethane casting produces end-use, rigid or flexible plastic parts with high durability, fast lead times, and production-level quality for your parts. We’ve created this guide to give you tips on creating highly accurate parts with a wide variety of cosmetic finish options.

Download Guide