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Should I use urethane casting or 3D printing?
3D print one to about ten parts: it is faster and needs no mold. Choose urethane casting for about 10–200 parts that need a molded look, molded-in color, clear or rubber-like material, or a production-like finish: a $500–$2,500 master and silicone mold yields 20–25 parts per mold, and first parts ship in 1–2 weeks.
Which is cheaper at your quantity?
The same housing, each process in a suitable material (Cast urethane and PC).
| Quantity | Urethane casting | 3D printing |
|---|---|---|
| 10 | $136 | $40.20 |
| 50 | $81.50 | $35.50 |
| 100 | $71.40 | $33.70 |
| 500 | $68.60 | $31.70 |
| 1,000 | $68.20 | $31.70 |
| 5,000 | $68.00 | $31.70 |
| 10,000 | $67.90 | $31.70 |
| 50,000 | $67.90 | $31.70 |
| 100,000 | $67.90 | $31.70 |
Where each pays off
Urethane casting
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- Tooling
- 3–7 days for master and silicone mold
- First article
- 1–2 weeks
- Production
- 2–3 weeks for up to about 200 parts
About ±0.010 in (±0.25 mm) on features under a few inches; about 0.15% shrink
Additive manufacturing
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- First article
- 2–7 days for plastic; 1–3 weeks for metal
- Production
- 1–3 weeks per release
SLS/MJF ±0.3% (±0.012 in / ±0.3 mm minimum); SLA about ±0.005 in (±0.13 mm) over the first inch; FDM about ±0.010 in (±0.25 mm)
Which should you pick?
Pick Urethane casting when
- You need 10–200 parts for pilots, betas or trade-show builds
- Parts need molded-in color, clear material or soft-touch grades
- The surface should copy a polished or textured master
- Parts must look like the molded production version
Pick 3D printing when
- You need one to about ten parts
- The design changes between builds
- The part has internal channels, lattices or printed-in-place assemblies
- Functional nylon parts are needed in 2–7 days
Key differences
| Urethane casting | 3D printing | |
|---|---|---|
| Tooling | Master and silicone mold, $500–$2,500 | None |
| Surface | Copies the master, from high gloss to texture | SLS/MJF Ra 250–500 µin (6–13 µm); SLA under 63 µin (1.6 µm) |
| Materials | Polyurethanes simulating ABS, PC, PP and rubber; clear grades | PA12, PA11, TPU and resins; metals |
| Tolerance | ±0.010 in (±0.25 mm), about 0.15% shrink | SLS/MJF ±0.3%, minimum ±0.012 in (±0.3 mm); SLA ±0.005 in (±0.13 mm) |
| Lead time | First parts in 1–2 weeks | 2–7 days for plastic |
| Geometry | Must release from a silicone mold; sections under about 0.5 in (13 mm) | Internal features possible; needs powder escape holes |
Questions
Is urethane casting better than 3D printing?
For 10–200 parts that need a molded look, color, or clear or rubber-like material, yes. For one to about ten parts, or designs still changing, 3D printing is faster and cheaper.
Where does the urethane casting master come from?
Usually a 3D print, such as an SLA part sanded to finish, or a machined part. The two processes often work together: print one master, then cast the run.
How strong are cast urethane parts compared with printed parts?
Rigid urethanes simulate ABS or polycarbonate at about 6,000–10,000 psi (40–70 MPa) tensile. Printed PA12 runs about 7,000 psi (48 MPa). Both are close to, but not the same as, the production plastic.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.