Process

Using silicone molds cast on 3D-printed matrices, this method is ideal for manufacturing prototypes since it simulates the injection molding process. This process can be used to make rigid or flexible, opaque or transparent parts while offering various advantages:

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Low-cost tooling, a more cost-effective option for low production volumes and/or large parts

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Economical commercialization costs for short production runs

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More creative possibilities as this process can easily reproduce complex details and can integrate thin and thick walls in the same part

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Easy encapsulation of inserts and delicate components as the process uses low pressure and temperatures

Potentially reduced assembly costs and resolution of seal issues

Materials

We offer a wide range of urethane and silicone resins. Urethane resins for prototyping are selected to replicate, as much as possible, the characteristics of the thermoplastic resin that will ultimately be used for mass production. Options include resins that comply with flammability standard UL 94 V-0 and FDA requirements. We encourage you to speak to our technical advisors to make the best choice.

Rigid urethanes

  • Available in 60D to 90D hardnesses
  • Resin can be in the colour of your choice
  • ABS, PP, PP GF10, PP GF30, PC-ABS and Nylon equivalents available
  • Good shock-resistance
  • Option to add 1/32’’ fiberglass or braided strips in the material

Flexible urethanes

  • Available in 10A to 95A hardnesses
  • Resin can be in the colour of your choice
  • Excellent tear and elongation resistance
  • Available resin options with good resistance to oil and gasoline
  • Excellent abrasion-resistance

Medical resins

  • Available in 20A and 85D hardnesses
  • Urethane and silicone resins available
  • Suitable for food processing
  • Medical devices
  • Biocompatible resin

Silicones

  • Available in 12A to 60A hardnesses
    Translucent or coloured
  • Food-grade certified
  • Usable for food applications (e.g. molds for chocolate, ice cubes and confectionery)
  • High resistance to pulling and tearing
  • Skin safe SORTA-Clear 18 resin available

Flexible and rigid foams

  • Available in different densities
  • Urethane and silicone resins available
  • Option to colour the foam
  • Rigid foams are durable and can be sanded and machined
  • Flexible foams are used for padding, cushioning and many other applications
  • Option to create a uniform skin on the surface
  • Some available resins are certified compliant with flammability standard UL 94 HB

Flame retardant urethane

  • Resin certified compliant with flammability standard UL 94 V-0
  • Minimum 1.6 to 3 mm wall, depending on the resin
  • Impact resistant
  • Option to use TC-885 FR resin, certified for use in the aeronautics industry
  • 40A to 90D hardnesses available

Transparent resins

  • 40A to 90D hardnesses available
  • Minimum 1.6 to 3 mm wall, depending on the resin
  • Impact resistant
  • Option to use TC-885 FR resin, certified for use in the aeronautics industry
  • Optical lens manufacturing
  • UV resistant
  • Resin can be in the colour of your choice
  • Perfect transparency
  • Casting thickness of 1/16” to 6”
  • Refractive index of 1.50084

High temperature urethanes

  • Available in flexible or rigid forms
  • Resist temperatures up to 174°C / 346°F

RoHS and REACH resins

  • The majority of our resins are certified RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorization and Restriction of Chemicals) compliant by our manufacturers. Documentation available upon request.

Tolerances

Tolerances vary depending on the resin. In general, a tolerance of ±0.015" should be provided for the first inch and ±0.003'' for each additional inch. Part geometry and wall thickness can affect tolerancing. Be sure to tell us which dimensions are the most critical.

Hardness scale

Surface finishes


Smooth (untextured)

Mold-Tech equivalent:
MT-1000

F0.5

Mold-Tech equivalent:
MT-11010

F1

Mold-Tech equivalent:
MT-11020

F2

Mold-Tech equivalent:
MT-11030

F3

Mold-Tech equivalent:
MT-11040

F4

Mold-Tech equivalent:
MT-11050

F5

Mold-Tech equivalent:
MT-11060