Before talking about the cost, some people might not be familiar with what Urethane Casting is and what advantages it offers. So let’s take a look first.
What Is Urethane Casting?
Urethane Casting (also known as vacuum casting or silicone molding) is a manufacturing process that uses silicone molds and polyurethane (PU) materials to produce plastic parts. It offers several key advantages: low mold-making costs, short lead time, and excellent surface finish and functionality similar to injection-molded parts.
However, this process also has some limitations:
- Short mold lifespan — silicone molds typically last for only 20–30 copies.
- Higher unit cost at larger volumes, which erodes its cost advantage.
- Limited material performance — while PU resins are versatile, they may not match engineering plastics in terms of high-temperature or high-strength applications.
Therefore, vacuum casting is suitable for small-batch production of plastic parts that do not require high strength or heat resistance.
How Much Does Urethane Casting Cost?
After learning about urethane casting, the most impressive feature is its cost-effectiveness. But how does it cost? To answer this, we need to examine the entire production process.
The Complete Urethane Casting Process: 3 Key Stages
- Master Pattern Creation A high-precision prototype (master pattern) must first be produced, typically through CNC machining or 3D printing. This master serves as the original for replicating silicone molds.
- Silicone Mold Reproduction The master pattern is placed in a molding box where liquid silicone is poured and cured, creating flexible production-ready molds.
- PU Part Casting Polyurethane material is injected into the silicone mold under vacuum conditions. After heat curing, the final plastic components are demolded.
As evident from this process, the primary costs of vacuum casting break down into:
- Master pattern cost
- Silicone mold cost
- Per-part production cost
The following section will examine each of these cost components in detail.
Master Pattern Cost
Before producing a silicone mold, a high-quality master pattern is essential. The master pattern serves as the original model for creating silicone or metal molds. Its surface finish and dimensional accuracy directly determine the quality of all replicated parts, influencing the final product’s precision and detail. Master patterns are typically manufactured via CNC machining or 3D printing.
Cost factors:
Manufacturing Methods:
- 3D Printing: Fast, suitable for complex structures, price usually starts from $50.
- CNC Machining: Suitable for regular structures requiring high precision, cost typically starts from $100.
Size and Complexity: Larger volume and more details lead to higher costs. Additional surface treatments (such as painting, polishing) will also increase expenses.
Materials Used: Master patterns commonly use resin or ABS-like materials. For higher precision, engineering plastics like aluminum or POM may be used, which will be more expensive.
The master pattern is a one-time investment and can typically be used to replicate multiple silicone molds, so its cost gets amortized in large-volume projects. However, for projects with only one mold and small quantities, this cost still needs careful consideration.
💡Tip: For very small runs, 3D printing may seem faster and more cost-effective—but it often falls short in surface finish and detail fidelity. If appearance and texture matter, urethane casting is a better choice.
Silicone Mold Cost
The cost of silicone molds typically ranges from $200 to 3,000, depending on several factors:
Size: The mold price for small parts is generally around $200−500,while the cost for large or complex structures can reach approximately $1,200-3,000.
Silicone material: Silicone prices range from $100-300 per kilogram.
Structural complexity: If the product has undercut features or requires multi-cavity designs, the mold cost will increase by about 30%.
Production location: The cost of making molds in China is typically about 40% lower than in Europe or America.
The advantage of silicone molds lies in their short production cycle (3-7 days), and they are very suitable for small batch production (each mold has a lifespan of about 10-30 parts). However, if the demand reaches hundreds or even thousands of parts, metal molds (such as steel injection molds, which typically start at $5,000 and above, with a lifespan exceeding 100,000 cycles) are more recommended.
Part Production Cost
The production cost of each plastic part mainly consists of polyurethane material cost, labor cost, and auxiliary processing fees (such as post-processing, packaging, etc.).
For example, a medium-sized part (about palm-sized) typically uses 100-300 grams of material, with material cost around $10 per piece. Additionally, the silicone mold requires multiple manual operations like vacuum degassing, resin injection, and pressure curing, with labor cost approximately $10 per piece (varies by region). Depending on product requirements, there may also be subsequent processes like spraying, polishing, bonding or assembly, costing about $5. For transparent parts requiring polishing or special coatings, the cost would be higher. Therefore, the final per-piece cost is around $25.
It’s important to note that if the production quantity is too small, these costs (mold cost, labor cost, etc.) will be allocated to fewer pieces, resulting in higher per-unit costs. Conversely, when approaching the mold’s maximum lifespan, the per-unit cost reaches its lowest point.
Example of Urethane Casting Cost
Producing 20 ABS-textured housings, part dimensions approximately 150x100x60mm
Master pattern: 3D printing + post-processing ≈ $150
Mold:Single−cavitydomesticsiliconemold≈$300
Per-unit cost: 25×20=$500
Total approximate cost: $950
Finally, if you’re considering using urethane casting process to manufacture your plastic parts, please contact RJCmold. With over 20 years of experience in custom part manufacturing, RJCmold provides free engineering support to help you get started. Contact RJCmold today for a quote or design review.
Related Post:
What is the Difference Between Injection Molding and Vacuum Casting?
