Skip to main content: Vacuum-cast polyurethane (PUR hard) – Wide variety of materials with series-like properties

Vacuum-cast polyurethane (PUR hard) Wide variety of materials with series-like properties

System construction space

2000 x 1000 x 1000 mm

Available materials

Wide range of PUR materials with series-like material properties

Optional properties

Transparent, diffuse, impact resistant, elastic…

Lead time

5-15 days

Vacuum casting is ideal for duplicating models. Starting from a master model, a silicone mold is created which is then used to duplicate parts made from polyurethane (PUR plastic). Following the mold casting, 1zu1 carries out the desired surface finishing: we simulate any desired surface on the master models, which is then reproduced in the creation of the silicone mold. At 1zu1, we can therefore produce components that are indistinguishable from a later original injection-molded part. 

Materials

In terms of strength values, technical prototypes should be as close as possible to the subsequent series products. Our vacuum-casting process optimally meets all requirements in terms of usage properties and permanent load capacity. 1zu1 has different materials to make your desired plastic part possible.

 070085090.1092095GF100122
Shore D hardness68 ± 272 ± 480 ± 1828580 ± 284 ± 2
Density [g/cm3]1.081.151.21.20 ± 0.021.23 ± 0.021.14 ± 0.021.06 ± 0.02
Flexural strength [MPa]3080 105 10515080± 2100
Bending modulus of elasticity [MPa]5001200 2100 250045002300 ± 1002000
Tensile strength [MPa] 2540 60 708560 ± 265
Notch impact strength [kJ/m2] no break>50 71 70306094
Elongation at break [%]100257.515312-147
Thermal stability [°C]55787885858585
Shrinkage [mm/m]7353237
Base colordark graytranslucentcremewhitishlight grayblacktransp./diffused light
colorableblack onlyyesyesyesyes (dark color tones)black onlyyes
Final curing at 23°C7 days5 days1 day3 days3 days3 days4 days

Do you have high demands in terms of transparency, gloss level and light transmission? The casting resin 122 we use enables you to produce transparent molded parts such as displays, containers, light guides and lenses in your desired requirements. Its approximate characteristic values compared to the series materials polycarbonate (PC) and Plexiglass (PMMA) are shown clearly in the following table.

 122PMMAPC  
Colortransparenttransparenttransparent  
Translucency [%]>909288-90  
Refraction index1.501.491.58  
Density [g/cm3]1.06 ± 0.021.181.20  
Hardness [Shore D]84 ± 29082-84  
Bending modulus of elasticity [MPa]200028002100  
TG [°C]90>80>100  
Impact strength (Charpy smooth) [KJ/m2]94>11no break  

The final touch

Furthermore, the perfect coloring of the casting resins in accordance with RAL, Pantone, NCS, or based on your sample, guarantees optimum results. Here at 1zu1, we can use special painting techniques to treat the models on request. EDM texturing, high gloss, special effects (metallic, silver, partial) or subsequent varnishing finish the components. Individual color samples or color requests (RAL, NCS, Pantone) are possible.

The possibility of individual printing, laser marking as well as hot foil stamping is also available at 1zu1 in-house. 

 


Your advantages

  • Short lead time for production of components: first deliveries possible after 5-15 days
  • Duplication of models by vacuum casting with up to 1,000 parts
  • High accuracy: components hardly distinguishable from the original injection molded part, 
  • Surfaces according to customer requirements: high gloss, fine structures, varnishing, printing
  • Perfect coloring of the casting resins in accordance with RAL, Pantone, NCS or based on your sample

1zu1direkt

Vacuum-cast polyurethane (PUR)

Advice tailored to your needs

At 1zu1, we help you find the perfect solution by combining the best technology with a wide range of materials. And this is implemented in the shortest possible time and with the highest technical precision.

Challenge us. What can I do for your project?

Stefan Rädler

1zu1sales
area manager Germany
T +43 5572 33 333-842
stefan.raedler@1zu1.eu

» For perfectly implemented ideas, I propose new technological paths with my customers.«

In motocross and enduro, Stefan Rädler is on difficult paths.

Stefan Rädler

1zu1sales
area manager Germany
T +43 5572 33 333-842
stefan.raedler@1zu1.eu

» For perfectly implemented ideas, I propose new technological paths with my customers.«

In motocross and enduro, Stefan Rädler is on difficult paths.

Klaus Pichler

1zu1sales
area manager Austria
T +43 5572 33 333-838
klaus.pichler@1zu1.eu

»As a cyclist, I know that excellent technology is the key to speed – and therefore to success..«

Klaus Pichler spends his free time in the saddle – he and his road bike conquer Austria’s mountains with endurance and the right pedal stroke.

Sebastian Fink

1zu1sales
area manager CH / LI / Vlbg
T +43 5572 33 333-839
sebastian.fink@1zu1.eu

“When it comes to perfect prototyping, it’s safe to say that we are the right address.”

Sebastian Fink is a trained instrument maker and plays the bass clarinet – his personal anti-stress program.

The vacuum process enables fast, efficient and cost-effective production of desired structural and molded parts. In addition, two different materials (hard and soft) can be combined during production. Inserts (magnets, threads, inserts, etc.) can also be integrated into the component.

The production process takes place in a vacuum or under negative pressure. What is the effect of this vacuum? On the one hand, it ensures bubble-free processing of the material. On the other hand, flow resistance within the mold caused by air pockets is avoided. This means that at 1zu1, we can achieve homogeneous, pore-free material properties.

  • From master model to casting mold:
    • Casting in vacuum
    • For simple components directly via a casting mold in 3D printing or milling technology: For series application 1zu1 recommends 100 to 200 pieces.
  • 3D printing of silicones: 
    • Discharging the material via nozzles or injecting a catalyst into a silicone bath 
    • Cantilevered components are possible 
    • Layered structure visible 
  • Vacuum casting materials: use of original silicone, including food-grade silicone

Polyurethane is the collective chemical term for elastic to hard plastics produced from polyalcohols and polyisocyanates. The curing reaction is a polyaddition. Polyurethanes have many uses, e.g. for the production of household sponges, adhesives, paints and floor coatings. Synthetic textile fibers such as polyurethane are also used in the fashion sector.

SHORE hardness, named after Albert Ferdinand Shore, is an indicator used primarily for elastomers and rubber-elastic polymers. It is directly related to the penetration depth and is thus a measure of the material hardness.

Elastomer materials (PU rubber) are available in various degrees of hardness from  30-90 Shore A. Thermoplastic-like materials are available in degrees of hardness from 45-85 Shore D.

Shore A3040506070809095    
Shore D      455560657080

Surface finishes

Here at 1zu1 we can treat master models, duplicated parts and serial parts with special surface techniques according to customer requirements . We finish the prototypes and serial parts via EDM texturing, high gloss, special effects (metallic, silver, partial) or subsequent varnishing.

We can also accommodate individual color samples or color requests (RAL, NCS, Pantone). For this purpose, we offer a wide range of surface treatment processes in manual finishing, depending on the initial technology. Each process can be applied individually, in combination, partially or fully, according to RAL or NCS.

The possibility of individual printing, laser marking as well as hot foil stamping is also available at 1zu1 in-house. Put us to the test!

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