Custom Polyurethane Casting & Molding

FallLine has supported manufacturers and industrial customers with precision custom urethane molding solutions for more than 40 years. Our experience enables us to serve applications in which material performance, dimensional accuracy, and production consistency are critical.

Every project begins with a clear understanding of the part’s operating environment, physical requirements, production volume, and performance expectations. From there, our team helps determine the right urethane formulation, tooling approach, and casting process to support the final component’s intended use.

Whether you need a large molded polyurethane component or repeat production of smaller urethane parts, FallLine brings the technical expertise and manufacturing flexibility needed to support reliable, scalable polyurethane casting programs.

FallLine manufactures molded urethane components using an array of polyurethane formulations, each selected for specific performance properties and application requirements.

At the core, polyurethane chemistry involves the use of an isocyanate and a polyol. These materials are commonly categorized into two primary groups: ethers and esters. Each group can be further refined into additional material families with different characteristics, including abrasion resistance, resilience, flexibility, hardness, and chemical compatibility.

Our team provides guidance on material selection after reviewing your project and discussing the physical specifications that affect part performance. This allows us to match your custom polyurethane casting project with a material that supports the right balance of durability, flexibility, and precision.

FallLine’s custom polyurethane casting and molding capabilities support a wide range of part geometries, production requirements, and performance demands. For manufacturers evaluating a specific cast urethane component type, our team can help determine the right formulation, tooling approach, and production process for your application.

If your project is focused on a particular custom-molded part or product category, explore our Cast Urethane Parts & Products to learn more about the types of cast urethane solutions FallLine manufactures.

FallLine also works with original equipment manufacturers that need ongoing support for engineered urethane components, production planning, and repeat manufacturing programs.

Whether you need a large custom urethane part or higher-volume production of smaller molded components, FallLine can help move your project from material selection and tooling through approved production.

FallLine helps customers move from concept to completed custom molded urethane components with practical guidance at every stage. Our team can assist with material selection, mold design, manufacturability, performance targets, and production planning.

Because every molded urethane project has different requirements, we focus on aligning the casting and molding process with your application rather than forcing a one-size-fits-all approach. The result is a custom molded urethane solution engineered for durability, precision, and dependable performance.

FallLine’s custom polyurethane casting and molding process is designed to produce durable, consistent urethane components that match your specifications. Our team works closely with you through each stage to ensure the final part performs as intended.

1. Project Review & Requirements
   We begin by reviewing your drawings, samples, application details, production volume, dimensional requirements, and performance expectations. This step helps us understand the physical demands placed on the part, including load, abrasion, impact, chemical exposure, temperature, and operating conditions.
2. Material Selection
   Once the application requirements are understood, our team recommends a polyurethane formulation based on hardness, flexibility, wear resistance, load-bearing capacity, chemical resistance, and other critical performance factors. We offer a broad range of proven urethane compounds and can help identify the right material for your project.
3. Tooling & Mold Creation
   Using our in-house machine shop, FallLine builds the tooling required for polyurethane casting and molding. Depending on your part geometry, tolerances, aesthetics, and expected production volume, we can produce soft tooling, hard tooling, single-cavity molds, multi-cavity molds, or more advanced production tooling.
4. Casting Polyurethane
   During the casting stage, the selected urethane formulation is prepared, poured, and processed according to the required material specifications. The casting polyurethane process allows FallLine to produce custom shapes, configurations, and performance characteristics that may be difficult to achieve with other materials or manufacturing methods.
5. Curing & Finishing
   After casting, parts are cured under controlled conditions to help achieve the required physical properties. Depending on the project, finishing steps may include trimming, machining, surface preparation, or other secondary operations.
6. Quality Inspection
   Before production is approved, parts are inspected against the required specifications. FallLine’s focus on process control, tooling accuracy, and material consistency helps ensure that every custom polyurethane molding project meets performance and dimensional expectations.

Polyurethane is valued for its versatility, durability, and ability to be engineered for specific performance demands. FallLine offers a wide range of urethane compounds, including materials from 40 Shore A to 80 Shore D, allowing us to match hardness and flexibility to the needs of your application.

By adjusting hardness, formulation, and design, FallLine can help balance abrasion resistance, flexibility, impact strength, and load-bearing capability within a single custom polyurethane casting project.