Comparing Urethane Casting and Injection Molding: Differences and Applications

Injection molding tooling

From the perspective of an experienced project manager and product development manager, I’ve been in the business of offering assistance to others in the manufacturing industry for years. From prototype design to mass production, I’ve dedicated myself to helping clients achieve their product development and manufacturing goals.

Along the way, I’ve often been asked about the differences between various manufacturing processes, particularly urethane casting and injection molding. Both methods have their unique advantages and suitable applications, but understanding the distinctions between them is crucial for selecting the right manufacturing method for your project.

In this article, I’ll share some insights into urethane casting and injection molding, exploring their similarities and differences, in hopes of helping you better understand and apply these manufacturing processes.

Let’s start by unraveling the fundamental principles behind urethane casting and injection molding, shedding light on how they operate, the materials involved, and the sequential steps of the manufacturing process.

Plastic injection molding

Manufacturing Processes and Principles

Urethane casting, often referred to as resin casting or polyurethane casting, is a versatile manufacturing method that involves pouring liquid polyurethane resin into a mold cavity. The mold is typically made from silicone or other flexible materials to facilitate the extraction of the finished part. This process is commonly used for producing prototypes, low-volume production runs, and complex geometric shapes that are challenging to achieve with traditional machining methods.

In contrast, injection molding is a high-volume manufacturing process primarily used for producing large quantities of identical parts. It entails injecting molten material, such as plastic or metal, into a mold cavity at high pressure. The mold, usually made from hardened steel, comprises two halves: the core and cavity. Once the molten material cools and solidifies inside the mold, the two halves separate, and the finished part is ejected.

Both processes require specific materials tailored to their respective applications. Urethane casting typically utilizes polyurethane resins, which come in various formulations to accommodate different mechanical properties, colors, and surface finishes. Injection molding, on the other hand, employs thermoplastics, thermosetting polymers, or metal alloys, depending on the desired characteristics of the final part.

What is the process of urethane casting?

Vacuum Casting with Rubber

The manufacturing process for urethane casting involves several steps, starting with the creation of a master pattern or 3D model of the part to be produced. Next, a mold is fabricated around the master pattern, and once cured, the mold is opened, and the pattern is removed. The mold is then prepared for casting by applying a release agent, and the liquid resin is poured into the cavity. After curing, the part is demolded, trimmed, and finished as needed.

What is the process of injection molding?

On the other hand, injection molding follows a more automated and continuous process. It begins with the design of the mold, which is typically machined from metal and consists of two halves: the cavity and core. The molten material is injected into the mold under high pressure, where it cools and solidifies to form the desired shape. Once the part has sufficiently cooled, the mold opens, and the part is ejected, ready for further processing or assembly.

In summary, while both urethane casting and injection molding are valuable manufacturing processes, each has its unique strengths and limitations. Understanding their principles and applications is essential for selecting the most suitable method for bringing your product to life.

What are the disadvantages of urethane casting?

Limited to low to medium production volumes, longer lead times compared to injection molding, limited material options, and potential for air bubbles or imperfections in finished parts.

Is urethane casting expensive?

Urethane casting can be more cost-effective than other manufacturing methods for low-volume production runs. However, it may not be as economical as high-volume processes like injection molding. The cost-effectiveness of urethane casting depends on factors such as part complexity, material selection, mold fabrication, and finishing requirements.

How thick should a wall be for urethane casting?

The thickness of a wall for urethane casting depends on various factors, including the material being used, the desired mechanical properties of the part, and the specific requirements of the application. In general, walls for urethane casting typically range from 0.040 inches (1 mm) to 0.250 inches (6 mm) thick.

Is urethane casting food safe?

Urethane casting resins are generally not considered food safe due to the potential for leaching of chemicals and additives from the resin into food or beverages. While some urethane materials may be certified as food-safe under specific conditions, it’s essential to consult with the manufacturer and conduct thorough testing to ensure compliance with relevant regulations and standards for food contact materials.

Thermoplastic injection molding

What is bad about injection moulding?

Injection molding can have disadvantages such as high initial tooling costs, longer lead times for tooling development, limited flexibility for design changes once the mold is made, and potential for material waste during setup and startup phases.

What are the 4 stages of injection molding?

  1. Injection: Molten material is injected into the mold cavity under high pressure.
  2. Cooling: The injected material cools and solidifies inside the mold.
  3. Ejection: The mold opens, and the finished part is ejected from the mold cavity.
  4. Clamping: The mold closes, and the cycle begins again for the next injection.

How long does injection molding last?


The lifespan of injection molding depends on various factors such as the material used, mold design, production volume, and maintenance. High-quality molds can last for hundreds of thousands or even millions of cycles with proper care and maintenance. However, molds may require refurbishment or replacement over time due to wear and tear, changes in product design, or shifts in production requirements. Plastic injection molds last from hundreds to over a million cycles, depending on factors such as material properties, mold design, and operating conditions.

Injection molding defects


When discussing the suitability of urethane casting and injection molding, it’s essential to consider their respective applications in different scenarios.

Urethane casting is often favored for manufacturing small-batch custom parts due to its flexibility in producing low volumes economically and relatively quickly. It offers the advantage of rapid prototyping and can accommodate intricate designs and complex geometries with ease.

On the other hand, injection molding excels in large-scale production, offering high efficiency, repeatability, and cost-effectiveness for mass production runs. Its automated process allows for high-volume manufacturing of identical parts with minimal labor and material waste.

Therefore, the choice between urethane casting and injection molding depends on factors such as production volume, part complexity, lead time requirements, and budget constraints.

injection molding

Cost Analysis

Analyzing the cost difference between urethane casting and injection molding involves examining various factors such as manufacturing processes, material expenses, and production efficiency. Urethane casting typically incurs lower initial tooling costs compared to injection molding, making it more suitable for small-batch production runs and prototyping.

Additionally, the flexibility of urethane casting allows for cost-effective adjustments to designs and iterations during the development phase.

However, injection molding offers higher production efficiency and economies of scale for larger volume production, offsetting its higher upfront investment. Material costs may also differ between the two processes, with urethane casting materials often being more expensive per unit compared to thermoplastic resins used in injection molding.

Therefore, the choice between urethane casting and injection molding depends on factors such as production volume, part complexity, lead time requirements, and budget considerations.

ABS silicone mold vacuum casting service (1)

Speed Comparison

Comparing the manufacturing speed between urethane casting and injection molding involves assessing the time it takes from design conception to final production, as well as identifying factors that may influence production speed.

Urethane casting typically offers faster turnaround times for small-batch production and prototyping due to its simplified tooling process and shorter lead times for mold fabrication. The flexibility of urethane casting also allows for quicker design iterations and modifications, enabling rapid prototyping and faster time-to-market.

In contrast, injection molding may require longer lead times for tooling development and setup, particularly for complex molds or large production volumes.

Additionally, factors such as material selection, part complexity, and machine availability can impact production speed in both processes. Therefore, the choice between urethane casting and injection molding depends on factors such as production volume, lead time requirements, and project timeline considerations.

custom black ABS plastic part injection molding services

Manufacturing Precision Comparison

When comparing urethane casting and injection molding in terms of production precision, several differences arise, particularly in surface smoothness and dimensional accuracy.

Surface Smoothness:

  • Urethane Casting: Typically offers a smooth surface finish, but may exhibit minor imperfections due to the nature of the casting process. Surface roughness can vary depending on factors such as mold quality and material viscosity.
  • Injection Molding: Known for producing parts with exceptionally smooth surfaces, thanks to the high-pressure injection of molten plastic into precision-machined molds. The use of polished molds and automated processes further enhances surface quality.

Dimensional Accuracy:

  • Urethane Casting: Provides good dimensional accuracy, with deviations typically within ±0.1 mm for small to medium-sized parts. However, variations may occur due to factors like material shrinkage and mold flexibility.
  • Injection Molding: Offers superior dimensional accuracy, often achieving tolerances as tight as ±0.025 mm or even better. The high-pressure injection process ensures consistent part dimensions, with minimal variation across production runs.

Example Data:

  • Urethane Casting:
    • Surface Roughness: Ra 1.5 μm
    • Dimensional Tolerance: ±0.1 mm
  • Injection Molding:
    • Surface Roughness: Ra 0.4 μm
    • Dimensional Tolerance: ±0.025 mm

blue ABS injection molding


Urethane Casting Materials:

  • Polyurethane (PU) resins: Offered in various hardness levels (shore hardness), ranging from soft elastomers to rigid plastics.
  • Silicone: Provides flexibility and excellent mold release properties, suitable for producing flexible parts and molds.
  • Epoxy: Offers high strength and chemical resistance, commonly used for producing durable prototypes and functional parts.

Injection Molding Materials:

  • Acrylonitrile Butadiene Styrene (ABS): Known for its impact resistance, toughness, and heat resistance, widely used in automotive, consumer goods, and electronics industries.
  • Polycarbonate (PC): Offers excellent optical clarity, high impact strength, and heat resistance, commonly used for transparent parts and electronic housings.
  • Polypropylene (PP): Provides good chemical resistance, low density, and excellent fatigue resistance, suitable for packaging, automotive components, and consumer products.
  • Polyethylene (PE): Available in various grades (e.g., HDPE, LDPE), offering chemical resistance, toughness, and flexibility, commonly used in packaging and piping applications.
  • Nylon (PA): Known for its strength, abrasion resistance, and low friction coefficient, suitable for producing gears, bearings, and mechanical components.

Example Comparison: Consider the production of a gear component:

  • Urethane Casting: PU resin with a high shore hardness can be used to produce a flexible gear with good impact resistance and noise dampening properties, suitable for low-volume applications where noise reduction is critical.
  • Injection Molding: Nylon (PA) is an ideal material choice for injection molding gears due to its high strength, wear resistance, and dimensional stability. Injection-molded nylon gears exhibit precise tooth profiles and consistent performance, making them suitable for high-volume production in automotive and machinery applications.

Since 2005, Modo Rapid has been dedicated to providing high-quality custom manufacturing services, covering a variety of processes such as Urethane Casting, CNC machining, and 3D printing. We understand the uniqueness and importance of each project, making us not just your manufacturing partner, but also your project supporter and innovation collaborator.

With years of experience and continuous technological innovation, our professional team is committed to providing customers with the best manufacturing solutions, ensuring the smooth progress and success of your projects. Whatever custom manufacturing services you need, we are here to meet your requirements.

Contact us today and let Modo Rapid’s professional team support your project and help you achieve greater success!