Castable urethane raw materials are liquid, which permits them to be pumped, metered, mixed and dispensed by machines under very precise control of temperature and ingredient proportions. Castable urethanes enter molds as a hot liquid at low pressure and are cured at an elevated temperature. This unique characteristic allows Gallagher to mold any shape and size. We can mold very large urethane parts with thick cross-sections which are completely uniform throughout.

  • Longer service life than plastics or conventional rubber
  • Soft as a sponge, hard as a rock or anywhere in between
  • Some formulations FDA-approved for food applications
Gallagher Guarantee

Explore some of the other benefits of castable urethane

Bonding to Metal and Plastic Inserts

A key advantage of cast polyurethane is its ability to be easily bonded to other materials – such as many types of metal, composites, and to both reinforced and unreinforced plastics – allowing you to enjoy the benefits of both materials.

These other components, commonly called inserts, can include bearings, wheel hubs, threaded fasteners, injection molded plastic components, G10 laminates, castings, etc. The bond is incredibly strong, exceeding, in most cases, the high tear strength of the bonded polyurethane.

The object in all cases is to reduce or eliminate areas of stress concentration. Replace sharp edges with chamfers or radii. Use designs which promote natural shaping of the urethane when under load

We also can successfully bond some thermoplastics to metals or other thermoplastics.

Polyurethane design-tips

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Low-Pressure Molding

Cast thermoset urethanes start out as liquid components that are accurately metered, mixed and dispensed by our special built machinery. Typically the pressures involved in dispensing do not exceed 100 psi (700 KPa) and on average are less than 10 psi (70 KPa). Unlike injection tooling which must withstand thousands of psi, tooling for cast polyurethane is usually much less expensive — great for prototyping and short- to medium-production runs.

Urethane Advantages vs. Metal, Plastics and Rubber

vs. Metal

  • Lightweight
  • Noise Reduction
  • Abrasion Resistance
  • Corrosion Resistance
  • Resilience
  • Impact Resistance
  • Flexibility
  • Easily Moldable
  • Non-Conductive
  • Non-Sparking
  • Often Lower Cost

vs. Plastics

  • High Impact Resistance
  • Elastic Memory
  • Abrasion Resistance
  • Noise Reduction
  • Variable Coefficient of Friction
  • Resilience
  • Thick Section Molding
  • Lower Cost Tooling
  • Lower Temperature Resistance
  • Resistance to Cold Flow (or Compression Set)
  • Radiation Resistance

vs. Rubber

  • High Abrasion Resistance
  • High Cut & Tear Resistance
  • Superior Load Bearing Capacity
  • Thick Section Molding Without a Cure Gradient
  • Colorability
  • Oil Resistance
  • Ozone Resistance
  • Radiation Resistance
  • Broader Hardness Range
  • Castable Nature
  • Lower Cost, Low Pressure Tooling