Polyurethane casting: Economical small series
Do you need complex prototypes, economical small series of up to 1,000 pieces or large-volume, heavy-duty components? Our polyurethane (PUR) casting process offers the ideal solution when injection moulding reaches its limits.
Low tool costs, maximum precision
As your development partner, we use the enormous flexibility of this process to produce extremely durable and precise components for you from the technical plastic polyurethane. You benefit from low tool costs and short development times — ideal for prototypes and series of up to 1,000 pieces.
Polyurethane mouldings for your application
We develop and manufacture complex PUR moulded parts that are tailored exactly to your application — ideal for prototypes, small and medium-sized series.
Economical from the first component
Thanks to low tool costs, the process is the ideal choice for the rapid and cost-effective production of prototypes, pre-series and small series.
Maximum freedom of design
The process makes it possible to implement the most demanding geometries, undercuts and variable wall thicknesses without compromises.
Large-volume components
We produce solid yet precise moulded parts weighing up to 200 kg for you, which are extremely stress-free as a result of the process.
Outstanding load capacity
Cast PUR elastomers are extremely wear-resistant, have excellent mechanical properties and are resistant to oils, greases and many chemicals.
Functional coatings for the highest loads
We coat ball bearings, cores or steel plates with high-performance polyurethane individually for your specific application.
Wear & functional protection
The PUR coating becomes the functional surface of your component. It allows use in demanding environments. Compared to rubber, the coating is significantly more abrasion resistant, meaning that the service life of your system is extended.
Seamless surfaces through rotational casting
Especially for roller, our rotary casting process ensures seamless, homogeneous coatings without molding costs. The Intec RTE system used for this purpose provides a high-performance coating for rolls.
Intelligent multi-module
coatings
We specifically combine hard and soft segments or produce so-called “sandwich roller” with specific damping or support properties.
Precise finishing
Each coated component is turned or ground precisely to the required final dimensions on our CNC machines — for maximum accuracy.
The material is decisive:
Polyurethane (PUR)
Polyurethane is an extremely versatile high-performance material. By specifically adapting the recipe, we can adjust the properties exactly to your needs — from extremely soft to very hard. Learn more about the outstanding material properties and the wide range of applications.
A seamless process for tailor-made quality
A perfect component is not created in the mould alone. It is the result of a consistently controlled process that starts well before casting and only ends after the final quality control. We take care of the entire chain of pre- and post-processing for you. You get a high-precision system component that can be integrated directly into your production without further intermediate steps.
The basis for perfect adhesion
We create the perfect basis for an indissoluble connection and maximum durability. Careful preparation of cores and inserts includes cleaning, sandblasting and applying specific primers. In this way, we guarantee permanently strong adhesion between metal and polyurethane — even under extreme loads.
The finish for maximum accuracy
After casting, we give each component the final, precise measurement on our modern CNC machining centers. Whether drilling, milling, turning or grinding — we ensure the tightest tolerances and perfect surfaces. Each individual component undergoes a careful final check before it leaves our house as a ready-to-install and tested solution.
With a passion for quality
In our technology center, we rely on modern polyurethane casting systems. Complemented by powerful CNC machining centers and our own tool shop, we can react flexibly, precisely and economically to your requirements at any time.
Our performance in figures
Our casting technology stands for precise and economical plastic solutions for small series and high-quality prototypes.
Up to this weight, we can produce solid mouldings precisely and reliably for you.
In this wide range, we adjust the Shore hardness exactly to your mechanical requirements.
We can seamlessly coat roller with a diameter of up to 1.5 meters using a rotary casting process.
Modern casting systems are available in our machinery for flexible and process-reliable production processes.
Polyurethane solutions from the casting process
See which products and components we have already successfully manufactured using our casting process.
Deflection roller
Cross-grooved roller with polyurethane coating for the conveyor belt drive ensures improved water drainage and uniform belt drive.
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Squeezing roller
Ideal for squeezing steel coils oil-resistant. Ether-based material has high load capacity and cut resistance. Polyurethane is significantly more abrasion resistant than NBR.
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Pressure roller
With openings possible, for steel and aluminum coils, highly dynamic loads of up to 25 tons.
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Baugruppen
Diabolo roll
Durable and wear-resistant plastic diabolo roller (roller) for safe guidance and stability in technical systems.
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Chain plates
Our extremely wear-resistant polyurethane can be used as a coating or a replaceable cushion. It offers mechanical strength, is noise-absorbing and ideal for noise-sensitive conditions.
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Coupling element
Elastic coupling element made of polyurethane for flexible transmission of driving forces, damping vibrations and shocks and for compensating radial and axial shaft displacements.
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Conveyor roller with chain drive
Conveyor roller with 75 Shore A polyurethane coating - Shore hardness can be individually adjusted.
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Baugruppen
Mixing blade
Abrasion-resistant polyurethane mixer blade - resistant to rust and chemicals. Lighter than metal, reduces energy consumption and makes handling easier.
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The suitable alternative for your project
Every project has its own requirements. If the casting process is not the ideal solution for your application, we will find the right path together. We offer you a wide range of manufacturing technologies and services to implement your ideas precisely and economically. This enables you to always access the best technology for your specific component.
Injection Moulding
Series production starting at approx. 1,000 pieces
The solution for maximum precision in series production. We produce large quantities of consistently high quality.
Assemblies
Small series to large series
We assemble complete components for you — including purchased parts, surface finishing and final testing. You get a ready-to-install solution from a single source.
Get in touch with us!
Lukas Többen
Product Manager PU Casting
Telephone:
+49 5491 9691-0Email:
sales@internorm.de