Cast molding is one of the most versatile manufacturing processes, offering a range of material and design options that fit your production needs. Whether you're creating a rapid prototype or scaling up for full production, cast molding can help you achieve complex shapes, precise geometries, and forms.

At MPC, we specialize in thermoset polyurethanes that offer durability and flexibility, making cast molding an ideal solution for custom components. Discover how our advanced cast molding process can bring your product designs to life - from concept to completion.

Key Benefits of Cast Molding 

• Wide material adaptability including thermoset polyurethanes
• Perfect for rapid prototyping to full scale production
• Capable of incorporating molded in subcomponents and unique surface finishes
• Multiple molding techniques available for customized product development

What is Cast Molding?

Cast molding is a manufacturing process that introduces liquid materials into a mold cavity where the material hardens into a solid state—similar to the process of molding chocolate. Once in a solid state, the result reflects the shape and surface of the engineered mold cavity. This technique is highly adaptable, with a wide variety of cast molding techniques and material options available to create a broad range of shapes, sizes, and forms.

Understanding The Cast Molding Process

The cast molding process can range from simple, manual operations by hand to fully automated systems with complex molding controls. This flexibility makes casting an optimal process for products requiring custom materials, varied volumes, or unique geometries.

Unlike injection molding or Reaction Injection Molding (RIM), cast molding is ideal for low to high production volumes and offers greater adaptability for custom designs. Multiple tooling techniques, such as open molds, closed molds, centrifugal molds, and compression molds, can be employed depending on the project requirements.

Want to learn more about cast molding tooling techniques? Click here to explore your options.

In addition, cast molding is an excellent solution for rapid prototyping in the desired material, enabling designers to test product functionality and performance before committing to full scale production.

The Benefits of Cast Molding

• Wide Range of Materials: Cast molding supports various materials, including engineered elastomers like thermoset polyurethanes
• Adaptability for Prototypes to Production: This versatile process is ideal to develop rapid prototypes for validation as well as manufacture small & large volume production runs.
• Customizable Products: With cast molding, you can incorporate molded in subcomponents and achieve unique surface finishes tailored to your specific design needs.

Things to Consider When Cast Molding

While cast molding is a flexible and efficient process, not all materials are ideal for this technique. The properties of the material will determine several aspects of the process.

For example:

• Metals typically require high heat and complex processes
• Thermoset polyurethanes, on the other hand, can be processed by hand or automated systems, making them a more versatile option for a wide variety of applications. 

Additionally, some geometries, such as undercuts, may pose challenges in the cast molding process. To avoid this, it's essential to work with a trusted manufacturing partner early in the design process to identify potential issues and optimize your design for manufacturability. 

Conclusion

Cast molding is an excellent solution for creating high-quality custom components, especially when flexibility in design and materials is a priority. By working with a trusted partner like MPC, you can ensure that your products are developed using the best casting process, material selection, and tooling techniques for your application.

Start Your Cast Molding Project Today!

If you believe cast molding with thermoset polyurethanes is the right process for your product design, we're here to help!

Complete our design tool, here, to get started, or download our material data sheets below to begin your custom product or component!