Fastest Service. Best Value. Superior Quality.
Over 55 Years of Excellence
Quick Turn Tooling and Precision Molding
Located on-site at our Minneapolis plant
Custom Molded Polyurethane
Rubber Industries: Our Many Services including Custom Molding of Polyurethane
At Rubber Industries, we offer all necessary services related to the molding of elastomers like polyurethane. Our services cover any project from start to finish and they can be fully customized to serve your needs.
We've been devoted to being a one stop shop for our customers for nearly fifty years. We've dedicated our expertise and investment into our plant and people to ensuring that we can provide the most comprehensive list of services. We perform all of the necessary design, material mixing, and manufacturing steps for your custom molded polyurethane project within our own facility here in the Minneapolis metropolitan area.
Brief Overview of Our Services
At Rubber Industries, we offer all necessary services related to the molding of elastomers like polyurethane. Our services cover any project from start to finish and they can be fully customized to serve your needs.
We've been devoted to being a one stop shop for our customers for nearly fifty years. We've dedicated our expertise and investment into our plant and people to ensuring that we can provide the most comprehensive list of services. We perform all of the necessary design, material mixing, and manufacturing steps for your custom molded polyurethane project within our own facility here in the Minneapolis metropolitan area.
Brief Overview of Our Services
- We can help you design the parts that you need. Our Computer-Aided Design (CAD) experts can take your idea and turn it into a fully functioning part.
- We can create all of the custom tooling needed for your project at our Minneapolis area facility on 5 acreas that we use to produce your product. We don't have to rely on an outside source for tooling.
- We handle the prototyping of your product at our facility, too. Before you decide to commit to a manufacturing run, we give you the opportunity to see a working prototype of your product.
- No one is faster from tooling through prototyping and production, while also custom in house mixing of your material, all on site.
- Our staff works around the clock at all times to handle the production of your product. This devotion to our work makes us the fastest from design to shipping you parts because your product is never left sitting for another work day to start.
Polyurethane Custom Molded Parts
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Not only can we provide the services necessary to go from your project's beginning to its end, but we also offer the largest selection of molding methods, techniques, and materials, for our custom molded items, too.
We provide rapid prototyping and production of polyurethane as well your custom tooling on site here in our Minneapolis area facility.
Our Molding Methods
We provide rapid prototyping and production of polyurethane as well your custom tooling on site here in our Minneapolis area facility.
Our Molding Methods
- Injection molding
- Compression molding
- Transfer molding
- Overmolded capabilities
Custom Molded Polyurethane
These blue polyurethane custom molded parts are used for protecting rotors on helicopters. These are the smallest of the ones we make for this application. These are approximately 20 inches long. Notice the undercuts, the nipples with the flanges, along with many other challenges. We mold many shapes of these up to 36 inches long by approximately 20 inches wide.
Not many companies can work at this level of detail with a very expensive material. You can count on Rubber Industries, Inc for custom molding your polyurethane parts!
Not many companies can work at this level of detail with a very expensive material. You can count on Rubber Industries, Inc for custom molding your polyurethane parts!
Polyurethane: A Brief Introduction To Our Work With PU
Polyurethane is also known as PU. PU is one of the most unique elastomers in existence and it is also very expensive to use for manufacturing. This isn't a negative, though. The products made with PU are very high quality when made properly. So, it's important to make sure that the manufacturing company that you choose to work with is extremely qualified to handle such an expensive material.
Rubber Industries is a company built on expert level knowledge and skill. We frequently work with PU and have the ability to properly use the material. Our knowledge and state of the art machinery also prevents any mishaps that would lead to ruined materials.
A lot of our competitors create their PU items by pouring them. We do not. We only use custom molding techniques to mold your PU as efficiently as possible and we only use our steel tooling to mold your PU items. Steel tooling is the most cost effective way to go about molding this material because we don't have to replace the tooling mid-production and we don't have to worry about our high quality steel becoming damaged like the less durable aluminum tooling that some of our competitors use.
PU can be used in combination with our custom colors to create an item that fits your project perfectly.
We have a quick high volume capability with injection molding of PU that allows us to get your PU project to market as soon as possible.
Our high volume molding and low volume production gives you the freedom to order as many items as you need. You're not forced to order extra items made from this expensive material just to get us to work with you. We will happily take on a low volume production run with the same effort that we put into our high volume runs.
PU is not a straightforward material to mold, but we've perfected it. However, a lot of our competitors haven't. When your project timeline and financial investment is on the line, who will you trust with this very expensive material?
Rubber Industries is the expert for custom molding polyurethane based on our many years and various custom molded urethane and overmolded urethane parts.
Polyurethane is also known as PU. PU is one of the most unique elastomers in existence and it is also very expensive to use for manufacturing. This isn't a negative, though. The products made with PU are very high quality when made properly. So, it's important to make sure that the manufacturing company that you choose to work with is extremely qualified to handle such an expensive material.
Rubber Industries is a company built on expert level knowledge and skill. We frequently work with PU and have the ability to properly use the material. Our knowledge and state of the art machinery also prevents any mishaps that would lead to ruined materials.
A lot of our competitors create their PU items by pouring them. We do not. We only use custom molding techniques to mold your PU as efficiently as possible and we only use our steel tooling to mold your PU items. Steel tooling is the most cost effective way to go about molding this material because we don't have to replace the tooling mid-production and we don't have to worry about our high quality steel becoming damaged like the less durable aluminum tooling that some of our competitors use.
PU can be used in combination with our custom colors to create an item that fits your project perfectly.
We have a quick high volume capability with injection molding of PU that allows us to get your PU project to market as soon as possible.
Our high volume molding and low volume production gives you the freedom to order as many items as you need. You're not forced to order extra items made from this expensive material just to get us to work with you. We will happily take on a low volume production run with the same effort that we put into our high volume runs.
PU is not a straightforward material to mold, but we've perfected it. However, a lot of our competitors haven't. When your project timeline and financial investment is on the line, who will you trust with this very expensive material?
Rubber Industries is the expert for custom molding polyurethane based on our many years and various custom molded urethane and overmolded urethane parts.
A List Of Our Most Commonly Used Elastomers
Our list of materials that we can use for your project is over two thousand entries long. We have amassed the knowledge and skill necessary to work with such a long and complex list of materials during our fifty years of service.
Our overmolding services are also a large part of our business and we offer several different non-elastomer materials that we can bond our elastomers to.
Non-Elastomer Materials For Overmolding
Overmolding accounts for a tremendous amount of our work and we are the experts in this field.
Our custom molded parts are used virtually in every type of segment of industry. Our products are used by the biggest brands and in the most demanding applications. They are utilized in everyday commercial items, or for the most demanding environments.
Industries Served
We can create nearly anything that our clients can possibly need, but we do have a few pieces that we make consistently for every industry that we serve.
Most Commonly Produced Items
Our list of materials that we can use for your project is over two thousand entries long. We have amassed the knowledge and skill necessary to work with such a long and complex list of materials during our fifty years of service.
- EPDM
- Butyl
- Natural rubber
- Silicone
- NBR (Nitrile)
- HNBR
- Polyurethane
- SBR
- FKM
- Neoprene
- Flourosilicone
Our overmolding services are also a large part of our business and we offer several different non-elastomer materials that we can bond our elastomers to.
Non-Elastomer Materials For Overmolding
- Stainless steel
- Brass
- Aluminum
- Glass-filled nylon
Overmolding accounts for a tremendous amount of our work and we are the experts in this field.
Our custom molded parts are used virtually in every type of segment of industry. Our products are used by the biggest brands and in the most demanding applications. They are utilized in everyday commercial items, or for the most demanding environments.
Industries Served
- Consumer
- Medical
- Automotive
- Industrial
- Petroleum industry
- Defense
We can create nearly anything that our clients can possibly need, but we do have a few pieces that we make consistently for every industry that we serve.
Most Commonly Produced Items
- Seals
- Grommets
- Bellows
- Diaphragms
- O-rings
- Gaskets
Urethane Molded Parts
The History Of PU
PU was first created in Leverkusen, Germany by Otto Bayer. The many different kinds of PU were intended as an alternative for polyester materials due to polyester being patented at the time of PU's creation.
The material was first used as a coating for aircraft during WW2 due to the many different advantages that it had over other materials that were available during the time. However, it was not available to the general public for many years and its use as a coating for aircraft was extremely limited.
In 1952, that all changed, though. PU became commercially available and it quickly became one of the most commonly used materials in the world. Now, it's among the top commercially used elastomers available.
After being introduced to the consumer market, chemists started creating different forms of PU's that were used to make gum rubber, foams that are still used today, and many of the elastomers that are used in modern manufacturing.
It wasn't long before DuPont began developing their own PU formulas and they quickly introduced polyether polyols. More specifically, they created polyglycol. The new form of PU quickly became the most popular PU. This was due to it being cheaper to manufacture and easier for workers to handle. It also had the benefit of added water resistance. A trait that opened PU's up for an even more varied list of uses.
The material had risen in popularity so greatly that 45,000 tons of PU foam was being created annually by 1960.
Monsanto and Bayer also joined the fray and began developing and selling their own PU formulas. Bayer's involvement with the production of PU formulas led to him creating the first plastic automobile by creating reaction injection molding (RIM).
With more formulas being created at an exceptionally high rate, PU became a multifunctional material that could be adapted for a myriad of applications.
The Chemical Make-Up Of PU
PU is a reaction polymer. This is the same category as unsaturated polyesters, phenolics, and epoxies.
PU is a general term that covers any elastomer created by causing an isocyanate to react with a complex polyol. This can be done through either a catalyst of some sort, or by using ultraviolet light to force the reaction.
The method and raw materials used to produce a PU are what allows PU to be adapted to so many different uses. By choosing different raw materials that match the requirements to make a PU, the resulting material can be imbued with a large variety of different benefits and each combination can be drastically different from other combinations.
By using different polyols and isocyanates, the resulting PU can be soft and pliable, extremely hard and durable, stretchy, or even foam-like. By adjusting the method of manufacturing and by including different additives, even more varied characteristics can be added to a PU. This flexibility of use and the ability to customize PU is what has made it such a common material.
One example of an additive being used to change the overall characteristics of a PU is in the creation of a PU foam. The most common way of manipulating the molecular chain of the isocyanate used in the PU to make the end product a foam is to simply add water. An isocyanate is an extremely reactive raw material that can change entirely with very minor additions. When water is added, the isocyanate reacts and connects to carbon dioxide gas that can be manipulated to create a foam.
The most commonly used isocyanates are TDI and MDI. This is due to the two isocyanates being more reactive than available alternatives and they're cheaper to acquire. The polyols that are typically used are much more varied due to their impact on the traits of the resulting PU.
The chemistry of PU materials is still evolving to this day. Over the past two decades, there has been a rising interest in materials that leave a low carbon footprint. Due to this societal demand, many producers of polyols have formulated polyols from vegetable oil and other natural materials that have a low impact on the environment.
PU has an absolutely staggering number of benefits when it is made properly and the manufacturer knows what they're doing. However, there is one major flaw that PU exhibits. It isn't biodegradable. As mentioned above, there is a lot of interest in creating materials that have a low carbon footprint. This has led to PU manufacturers striving to find more efficient and environmentally friendly methods to achieve the same benefits of PU, but without the negative impact.
PU was first created in Leverkusen, Germany by Otto Bayer. The many different kinds of PU were intended as an alternative for polyester materials due to polyester being patented at the time of PU's creation.
The material was first used as a coating for aircraft during WW2 due to the many different advantages that it had over other materials that were available during the time. However, it was not available to the general public for many years and its use as a coating for aircraft was extremely limited.
In 1952, that all changed, though. PU became commercially available and it quickly became one of the most commonly used materials in the world. Now, it's among the top commercially used elastomers available.
After being introduced to the consumer market, chemists started creating different forms of PU's that were used to make gum rubber, foams that are still used today, and many of the elastomers that are used in modern manufacturing.
It wasn't long before DuPont began developing their own PU formulas and they quickly introduced polyether polyols. More specifically, they created polyglycol. The new form of PU quickly became the most popular PU. This was due to it being cheaper to manufacture and easier for workers to handle. It also had the benefit of added water resistance. A trait that opened PU's up for an even more varied list of uses.
The material had risen in popularity so greatly that 45,000 tons of PU foam was being created annually by 1960.
Monsanto and Bayer also joined the fray and began developing and selling their own PU formulas. Bayer's involvement with the production of PU formulas led to him creating the first plastic automobile by creating reaction injection molding (RIM).
With more formulas being created at an exceptionally high rate, PU became a multifunctional material that could be adapted for a myriad of applications.
The Chemical Make-Up Of PU
PU is a reaction polymer. This is the same category as unsaturated polyesters, phenolics, and epoxies.
PU is a general term that covers any elastomer created by causing an isocyanate to react with a complex polyol. This can be done through either a catalyst of some sort, or by using ultraviolet light to force the reaction.
The method and raw materials used to produce a PU are what allows PU to be adapted to so many different uses. By choosing different raw materials that match the requirements to make a PU, the resulting material can be imbued with a large variety of different benefits and each combination can be drastically different from other combinations.
By using different polyols and isocyanates, the resulting PU can be soft and pliable, extremely hard and durable, stretchy, or even foam-like. By adjusting the method of manufacturing and by including different additives, even more varied characteristics can be added to a PU. This flexibility of use and the ability to customize PU is what has made it such a common material.
One example of an additive being used to change the overall characteristics of a PU is in the creation of a PU foam. The most common way of manipulating the molecular chain of the isocyanate used in the PU to make the end product a foam is to simply add water. An isocyanate is an extremely reactive raw material that can change entirely with very minor additions. When water is added, the isocyanate reacts and connects to carbon dioxide gas that can be manipulated to create a foam.
The most commonly used isocyanates are TDI and MDI. This is due to the two isocyanates being more reactive than available alternatives and they're cheaper to acquire. The polyols that are typically used are much more varied due to their impact on the traits of the resulting PU.
The chemistry of PU materials is still evolving to this day. Over the past two decades, there has been a rising interest in materials that leave a low carbon footprint. Due to this societal demand, many producers of polyols have formulated polyols from vegetable oil and other natural materials that have a low impact on the environment.
PU has an absolutely staggering number of benefits when it is made properly and the manufacturer knows what they're doing. However, there is one major flaw that PU exhibits. It isn't biodegradable. As mentioned above, there is a lot of interest in creating materials that have a low carbon footprint. This has led to PU manufacturers striving to find more efficient and environmentally friendly methods to achieve the same benefits of PU, but without the negative impact.
The Many Uses Of PU
PU is used in all of the world's industries. Its ability to formed into many different types of materials has led to it being one of the world's most commonly used materials. It would be impossible to catalog all of the many uses of PU in the modern world, but the following will be a relatively short list of the most common uses for the material with a brief summary of each use.
The Most Common Uses Of PU
PU is often used as insulation when it's created as a foam. Due to its density and ability to retain heat, he performs admirably when used to insulate structures, containers, or anything else that needs to remain at a specific temperature range. The easiest way to find PU being used in this application is to look within the walls of your own home. The majority of the world's residential insulation is made using PU.
Another use for the foam form of PU is for the cushions of commercially available furniture. The foam cushions and back rests of nearly every couch, chair, or ottoman is made using PU foam. The density of the foam used varies greatly depending on the type of feel that the manufacturer wants the furniture to have. You can also find it in the seat of your car in the form of a very rigid foam that can resist impacts and damage.
PU can also be used as a coating that increases the durability and corrosion resistance of other items. This was the materials first use when it was created in 1937. It was a lightweight material that helped to protect WW2 aircraft from being damaged by the elements. Today, it's still used for similar applications and it's an essential material for the industrial sector. It's also frequently used to make recreational arts and crafts more durable and visually appealing.
Skateboard wheels are almost exclusively made from PU. In fact, PU is the only material that the majority of skateboarders will even consider using for their wheels. This is due to its abrasion resistance, corrosion resistance, and durability. Wheels that are made from PU can be used heavily for long periods of time without losing their shape and making skateboarding uncomfortable, but they're also soft enough to absorb the impact of tricks and any hazards that are present.
Bushings are often overlooked items that do a lot for the items that they're used on. Industry-specific machinery, tools, toys, and the skateboards mentioned above all use bushings to provide a cushioned space between metal pieces.
Tubing can also be made from PU. PU tubing manages to combine the benefits of plastic and rubber to create a tube that can withstand the most demanding environments and applications. The abrasion resistance, corrosion resistance, tensile strength, and flexibility of PU tubing is nearly unmatched by tubing made from other materials. This makes it able to be used in demanding environment applications where other materials would fail.
PU is used in all of the world's industries. Its ability to formed into many different types of materials has led to it being one of the world's most commonly used materials. It would be impossible to catalog all of the many uses of PU in the modern world, but the following will be a relatively short list of the most common uses for the material with a brief summary of each use.
The Most Common Uses Of PU
- Insulation
- Foam padding
- Coatings
- Skateboard wheels
- Bushings
- Tubing
PU is often used as insulation when it's created as a foam. Due to its density and ability to retain heat, he performs admirably when used to insulate structures, containers, or anything else that needs to remain at a specific temperature range. The easiest way to find PU being used in this application is to look within the walls of your own home. The majority of the world's residential insulation is made using PU.
Another use for the foam form of PU is for the cushions of commercially available furniture. The foam cushions and back rests of nearly every couch, chair, or ottoman is made using PU foam. The density of the foam used varies greatly depending on the type of feel that the manufacturer wants the furniture to have. You can also find it in the seat of your car in the form of a very rigid foam that can resist impacts and damage.
PU can also be used as a coating that increases the durability and corrosion resistance of other items. This was the materials first use when it was created in 1937. It was a lightweight material that helped to protect WW2 aircraft from being damaged by the elements. Today, it's still used for similar applications and it's an essential material for the industrial sector. It's also frequently used to make recreational arts and crafts more durable and visually appealing.
Skateboard wheels are almost exclusively made from PU. In fact, PU is the only material that the majority of skateboarders will even consider using for their wheels. This is due to its abrasion resistance, corrosion resistance, and durability. Wheels that are made from PU can be used heavily for long periods of time without losing their shape and making skateboarding uncomfortable, but they're also soft enough to absorb the impact of tricks and any hazards that are present.
Bushings are often overlooked items that do a lot for the items that they're used on. Industry-specific machinery, tools, toys, and the skateboards mentioned above all use bushings to provide a cushioned space between metal pieces.
Tubing can also be made from PU. PU tubing manages to combine the benefits of plastic and rubber to create a tube that can withstand the most demanding environments and applications. The abrasion resistance, corrosion resistance, tensile strength, and flexibility of PU tubing is nearly unmatched by tubing made from other materials. This makes it able to be used in demanding environment applications where other materials would fail.
Rubber Industries Does More Than Just PU
Rubber Industries is a multifaceted company and we offer much more than just custom molded PU. We offer a nearly unlimited list of possibilities for your project by having the most comprehensive material catalog in the business. Besides PU, some of the other elastomers rubber we work with include:
We provide our services to all of the world's largest industries:
Our high volume capability with injection molding is made possible by our use of multiple modern injection presses to meet your specific project and all of your custom injection molding needs.
We don't only use the injection method to create our items. We also have the ability to perform transfer molding and compression molding.
Our high volume injection molding capability and our devotion to upholding the highest quality standards is the reason that the world's biggest brands come to us for all of their custom injection molding needs.
Our high volume injection molding is the fastest method to get large quantities of parts fast and economically without sacrificing the quality of your project. We have a quick high volume capability with injection molding that allows us to work faster than our competition and with more attention to detail and quality.
We create everything that we use from the ground up. This includes our custom tooling and custom colors. We have qualified mold builders (toolmakers) in house that build our molds from scratch and our qualified mixers can create any color that you need for your project in-house.
Our manufacturing process is able to be customized to such an extent that we can create most anything that your project requires. However, there is a list of items that we make most often. Our most frequently produced items are:
Rubber Industries has proudly made the highest quality elastomer items in the industry for fifty years. We've become the world's go to experts for elastomer-based projects and we uphold the highest standards to maintain that status.
Rubber Industries is a multifaceted company and we offer much more than just custom molded PU. We offer a nearly unlimited list of possibilities for your project by having the most comprehensive material catalog in the business. Besides PU, some of the other elastomers rubber we work with include:
- NBR (Nitrile)
- HNBR
- SBR
- Natural rubber
- Silicone
- EPDM
- Butyl
We provide our services to all of the world's largest industries:
- Consumer
- Medical
- Industrial
- Defense
- Automotive
- Petroleum and oil industries
Our high volume capability with injection molding is made possible by our use of multiple modern injection presses to meet your specific project and all of your custom injection molding needs.
We don't only use the injection method to create our items. We also have the ability to perform transfer molding and compression molding.
Our high volume injection molding capability and our devotion to upholding the highest quality standards is the reason that the world's biggest brands come to us for all of their custom injection molding needs.
Our high volume injection molding is the fastest method to get large quantities of parts fast and economically without sacrificing the quality of your project. We have a quick high volume capability with injection molding that allows us to work faster than our competition and with more attention to detail and quality.
We create everything that we use from the ground up. This includes our custom tooling and custom colors. We have qualified mold builders (toolmakers) in house that build our molds from scratch and our qualified mixers can create any color that you need for your project in-house.
Our manufacturing process is able to be customized to such an extent that we can create most anything that your project requires. However, there is a list of items that we make most often. Our most frequently produced items are:
- Seals
- Gaskets
- Bellows
- O-rings
- Diaphragms
- Overmolded items
Rubber Industries has proudly made the highest quality elastomer items in the industry for fifty years. We've become the world's go to experts for elastomer-based projects and we uphold the highest standards to maintain that status.
Polyurethane Molding Services
Polyurethane products, which are often referred to as urethanes, have become incredibly popular in recent years because the substance offers several unique benefits and items made out of it are relatively inexpensive to produce. Polyurethane is a multifunctional material that combines the rigidity of plastic with the flexibility of rubber, and it is used to make items ranging from shopping cart wheels to automotive hoses and bushings.
The substance is durable, pliable and can be used to make either hard or soft items. Rubber Industries Inc. has years of experience working with this innovative polymer, and we have used it to make items from basic seals to a helicopter rotor guard for defense industry applications. We generally recommend quick high volume capability with injection molding for poly-urethane items.
A little more background on Polyurethane
Polyurethane was developed in Germany by Otto Bayer in the 1930s. The work was part of IG Farben’s efforts to find a viable alternative to polyester, which could not be used by the company because it was protected by patents. Bayer and his colleagues soon discovered that the substance they had created was superior to plastic in several ways, but it did not go into wide-scale production until the 1950s.
The substance was initially produced in very small quantities by IG Farben, and nearly all of the poly-urethane that was made was used as a protective coating for aircraft. The mass production of Poly-urethane began in 1954, and annual output had climbed to 45,000 tons by 1960. The versatility and wide range of uses for the polymer attracted the attention of companies including DuPont, BASF and Dow Chemical, and soon there were several custom formulations on the market each with its own unique properties. The most successful of these formulas was polyglycol, which was developed by DuPont. This compound was embraced by manufacturers because it was inexpensive and extremely easy to work with.
The versatility of polyurethane became front-page news in 1969 when Bayer, the company not the scientist, unveiled a car with a body made entirely out of the substance. The car’s body had been made using the recently developed reaction injection molding process. During the process, a mixture of urethane and reactants are injected into a mold to produce complex shapes. The process was soon refined to allow reinforcing substances to be added to the mixture, which facilitated the manufacture of stronger items with improved thermal stability and reduced thermal expansion.
Car makers soon became enamored with the substance, which they used to make interior components, body panels, gaskets and air filter seals. The Pontiac Fiero, which was introduced in 1983, featured a body made out of poly-urethane. The most recent poly-urethane manufacturing innovation was the development of resin injection molding. This involves placing glass mats into the mold cavity for even greater stiffness and strength.
Polyurethane products, which are often referred to as urethanes, have become incredibly popular in recent years because the substance offers several unique benefits and items made out of it are relatively inexpensive to produce. Polyurethane is a multifunctional material that combines the rigidity of plastic with the flexibility of rubber, and it is used to make items ranging from shopping cart wheels to automotive hoses and bushings.
The substance is durable, pliable and can be used to make either hard or soft items. Rubber Industries Inc. has years of experience working with this innovative polymer, and we have used it to make items from basic seals to a helicopter rotor guard for defense industry applications. We generally recommend quick high volume capability with injection molding for poly-urethane items.
A little more background on Polyurethane
Polyurethane was developed in Germany by Otto Bayer in the 1930s. The work was part of IG Farben’s efforts to find a viable alternative to polyester, which could not be used by the company because it was protected by patents. Bayer and his colleagues soon discovered that the substance they had created was superior to plastic in several ways, but it did not go into wide-scale production until the 1950s.
The substance was initially produced in very small quantities by IG Farben, and nearly all of the poly-urethane that was made was used as a protective coating for aircraft. The mass production of Poly-urethane began in 1954, and annual output had climbed to 45,000 tons by 1960. The versatility and wide range of uses for the polymer attracted the attention of companies including DuPont, BASF and Dow Chemical, and soon there were several custom formulations on the market each with its own unique properties. The most successful of these formulas was polyglycol, which was developed by DuPont. This compound was embraced by manufacturers because it was inexpensive and extremely easy to work with.
The versatility of polyurethane became front-page news in 1969 when Bayer, the company not the scientist, unveiled a car with a body made entirely out of the substance. The car’s body had been made using the recently developed reaction injection molding process. During the process, a mixture of urethane and reactants are injected into a mold to produce complex shapes. The process was soon refined to allow reinforcing substances to be added to the mixture, which facilitated the manufacture of stronger items with improved thermal stability and reduced thermal expansion.
Car makers soon became enamored with the substance, which they used to make interior components, body panels, gaskets and air filter seals. The Pontiac Fiero, which was introduced in 1983, featured a body made out of poly-urethane. The most recent poly-urethane manufacturing innovation was the development of resin injection molding. This involves placing glass mats into the mold cavity for even greater stiffness and strength.
The Advantages of Using Polyurethane
Polyurethane remains extremely popular for a diverse range of applications because it offers manufacturers benefits that plastics and rubber compounds do not. The advantages of making parts out of the substance include:
Polyurethane remains extremely popular for a diverse range of applications because it offers manufacturers benefits that plastics and rubber compounds do not. The advantages of making parts out of the substance include:
- Density range: Poly-urethane can be molded into items that are a soft as a seat cushion or as hard as a bowling ball. The Shore A scale is used to rate softer durometers and the Shore D scale ranks harder durometers. Polyurethane can be manufactured from 20 Shore A to 85 Shore D. No other polymer with this type of physical characteristics is this versatile.
- Flexibility: When the polymer is custom molded, its flexural properties can be manipulated to improve elongation and recovery. This gives the substance outstanding elastic memory, which is why it is often used in demanding environments.
- Tear, impact and abrasion resistance: Poly-urethane’s high tensile properties give it better abrasion, impact and tear resistance than most synthetic rubber compounds. This durability is the why the polymer is often chosen for parts that will experience severe wear.
- Load bearing capability: While softer poly-urethane compounds may change in shape slightly when a heavy loads are placed on them, they quickly return to their original shape once the load has been removed. Rubber Industries Inc. has a team of in-house chemists experienced in formulating poly-urethane for a wide range of applications, and we have made components out of the substance for manufacturers virtually in every type of segment.
- Resists oil, grease and water: The polymer remains stable and displays only minimal signs of swelling when exposed to water, oil or grease. It is also capable of enduring prolonged exposure to seawater, which is why it is sometimes used to make marine impellers.
- Excellent bonding properties: Poly-urethane bonds well to a variety of materials including stainless steel, aluminum and brass as well as other plastics. This is one of the main reasons why the substance is commonly used to make overmolded wheels and rollers. Rubber Industries Inc. has made thousands of custom overmolded components out of the polymer and is recognized as the industry leader in this area.
- Insulating properties: Like rubber, poly-urethane has excellent electrical insulating properties and is appropriate for items that will be exposed to high voltage.
- Custom colors: Rubber Industries Inc. can add pigments to poly-urethane to produce items in a huge range of custom colors. Our chemists can also add ultraviolet shielding to ensure that these colors do not fade when exposed to sunlight.
- Mold, fungus and mildew resistance: Items made out of poly-urethane are suitable for use in humid conditions because they do not support fungal, mildew or mold growth. This is why the FDA has approved using the polymer even for the most demanding environments.
- Resiliency: The resilience of poly-urethane ranges from 10 percent to 65 percent depending on the formulation. This makes the substance ideal for shock-absorbing components like O-rings.
- Suitable for harsh environments: Poly-urethane resists corrosive chemicals and can withstand both high and low temperatures, which is why it is commonly used in demanding environments by the petroleum industry.
- Shorter lead times: Turning around orders is generally accomplished more quickly when poly-urethane is selected because the substance is so easy to work with. Rubber Industries Inc. has several tooling bases in stock to create custom products like diaphragms, bellows and gaskets to reduce lead times even further. When custom tooling is required, we can often complete the work in days, not months.
- Lower production costs: manufacturers often choose to make prototypes out of poly-urethane as the substance is less expensive than many synthetic rubbers and requires little or no finishing after being molded.
Polyurethane's Disadvantages
While poly-urethane has several qualities that appeal to manufacturers such as its abrasion resistance and versatility, it does have some drawbacks that make it more expensive or unsuitable for some applications. The disadvantages of making custom molded products out of polyurethane include:
How Polyurethane Is Used
Polyurethane is all around us. Foam made out of the substance insulates homes and fills mattresses and cushions, and items molded out of it are used by manufacturers in virtually all industrial segments. Some of the most common uses of molded poly-urethane in the industrial, consumer, automotive, medical and defense sectors include:
While poly-urethane has several qualities that appeal to manufacturers such as its abrasion resistance and versatility, it does have some drawbacks that make it more expensive or unsuitable for some applications. The disadvantages of making custom molded products out of polyurethane include:
- It’s not biodegradable: Biodegradability has become a serious issue for manufacturers in recent years as concerns about the environment have grown stronger. Several chemical manufactruers including DuPont and Dow are currently researching and testing environmentally friendly polymers that provide the benefits of poly-urethane.
- Does not cope well with solvents: For applications that will expose molded items to powerful solvents, polymers such as nitrile, fluorosilicone and EPDM may be more appropriate than poly-urethane.
- It’s flammable: Poly-urethane is not flame resistant and can emit toxic fumes when burned. Rubber Industries Inc. chemists can reduce these risks by formulating compounds that retard combustion, delay ignition and reduce surface burning.
How Polyurethane Is Used
Polyurethane is all around us. Foam made out of the substance insulates homes and fills mattresses and cushions, and items molded out of it are used by manufacturers in virtually all industrial segments. Some of the most common uses of molded poly-urethane in the industrial, consumer, automotive, medical and defense sectors include:
- Industrial: Poly-urethane’s unique properties make it a popular choice for seals and gaskets, and it is also used to make the recycling stars that sort materials in environmental facilities. Many manufacturers have chosen to move away from rubber or synthetic rubber bushings in favor bushings made out of more durable and resilient poly-urethane.
- Automotive: All manner of car parts are made out of molded poly-urethane including seat belts, hoses and dashboards. The polymer is also used to make some truck tires due to its impressive load bearing capabilities.
- Consumer: Skateboard wheels, tennis racket grips and the outer shells of electronic devices are all usually made out of poly-urethane. The wheels on items ranging from suitcases to roller coasters are made using poly-urethane because the substance can be made soft enough to absorb minor surface imperfections but strong enough to resist wear.
- Medical: Companies in the health care sector use poly-urethane in short-term implants because the substance can be formulated to be strong yet biocompatible. The polymer is also used in hospital tubing due to its tear resistance and flexibility.
- Defense: The first use poly-urethane was put to was protecting military aircraft, and the substance is still used for this purpose today. It is also popular for many other defense applications because of its versatility and suitability for even the most demanding applications.
How Poly-urethane Items Are Made
Before poly-urethane components can be molded, the materials being used must be mixed thoroughly. These materials generally include a resin base, at least one curative and a dye or pigment to add color. Sulfur is often also added as an additional vulcanizing agent to improve the stability of the final product. Rubber Industries Inc. uses sophisticated meter-mix and dispense equipment to ensure that compounds are properly prepared before molding. Rubber Industries Inc. produces molded items in three ways.
Rubber Industries Inc. - Your Polyurethane Experts
Getting the most out of a polymer as versatile as polyurethane takes expertise and experience. Rubber Industry Inc. has been making items out of poly-urethane for decades, and we have become the preferred supplier of many of the world’s largest and most respected corporations.
Other elastomers rubber we work with include nitrile, EPDM, Viton, HNBR, neoprene and butyl, which are used to make items such as diaphragms, bellows, O-rings and grommets. FKMs like Viton have attracted a great deal of attention recently from both the media and manufacturers, but who will you trust with this very expensive material can be a difficult decision. The reasons why you should consider using Rubber Industries Inc. for your next poly-urethane project include:
Before poly-urethane components can be molded, the materials being used must be mixed thoroughly. These materials generally include a resin base, at least one curative and a dye or pigment to add color. Sulfur is often also added as an additional vulcanizing agent to improve the stability of the final product. Rubber Industries Inc. uses sophisticated meter-mix and dispense equipment to ensure that compounds are properly prepared before molding. Rubber Industries Inc. produces molded items in three ways.
- Compression molding: During this process, the poly-urethane mix is placed into a heated mold and then cured by a combination of pressure and heat. Much of the work must be done by hand, which makes compression molding slightly more expensive than other techniques. However, this is a popular way to produce poly-urethane items in low volume production runs.
- Transfer molding: When this approach is taken, the mixture is poured into a transfer pot instead of being placed directly into the mold. The compound is then forced into all of the mold’s crevices by a heated piston. Transfer molding is suitable for medium or low volume production and is especially suitable for making complex or overmolded items.
- Custom injection molding: High volume injection molding is how poly-urethane components are usually made when large quantities are needed. This is the preferred option for high volume production because the process can be almost completely automated. Rubber Industries Inc. has multiple modern injection presses to meet your specific project specifications and suggests custom injection molding to clients looking for the fastest method to get large quantities of parts fast and economically. When high volume injection molding is used to make items out of poly-urethane, the technique is a little different to the method used to create rubber components. Instead of using a liquid compound, poly-urethane pellets are put into a screw column where heat and pressure turn them into a moldable substance.
Rubber Industries Inc. - Your Polyurethane Experts
Getting the most out of a polymer as versatile as polyurethane takes expertise and experience. Rubber Industry Inc. has been making items out of poly-urethane for decades, and we have become the preferred supplier of many of the world’s largest and most respected corporations.
Other elastomers rubber we work with include nitrile, EPDM, Viton, HNBR, neoprene and butyl, which are used to make items such as diaphragms, bellows, O-rings and grommets. FKMs like Viton have attracted a great deal of attention recently from both the media and manufacturers, but who will you trust with this very expensive material can be a difficult decision. The reasons why you should consider using Rubber Industries Inc. for your next poly-urethane project include:
- Experience: Polyurethane is not a straightforward material to mold, and the machinery needed to mold items using reaction or resin injection are extremely expensive. Rubber Industries Inc. has invested heavily in state-of-the-art equipment in recent years, and we have multiple modern injection presses to meet your specific project goals. We are able to offer quick high volume capability with injection molding, and we have nurtured relationships with several Asian suppliers capable of extremely high volume production.
- Tooling expertise: Rubber Industries Inc. is known in the industry for our custom tooling capabilities. We often create tools in just days, and we choose not to use aluminum because durable steel tooling is the most cost effective approach both short term and long term. We also have a large stock of steel tools for commonly ordered items that can lower startup costs significantly.
- Responsiveness: We use the latest and most sophisticated machinery because they provide the fastest method to get large quantities of parts fast and economically. Rubber industries Inc. is committed to being the fastest from design to shipping you parts, and we can sometimes take projects from prototyping to production in a week or less.
- Fortune 500 clients: Companies including Ford, General Motors, DuPont and 3M have turned to Rubber Industries Inc. when they needed molded components because we are the experts in the field. They then became loyal clients because of our professionalism and outstanding customer service.
