Products include keypads, bumpers, boots, covers, wipers, gaskets, housings, bolts, nuts, insert-molded items; the list is only limited by your imagination.

Molds for castings can be made several ways:

From a master: (SLA, machined, supplied by the customer)
Molds can be made by casting around a master using either silicone or polyurethane material. The choice of material depends on the level of detail, mold life and what material will be used to cast the replicated parts. Silicone is often used for the mold if great detail is needed and urethane will be used for replications.
Polyurethane may be used for the mold if silicone is being used for the replications or the mold longevity are the most important factors.

Molds can be directly machined into acrylic:
This method is used if a CAD file can be provided and the part design is finished. For simpler part designs, this is a way of making a multiple cavity mold to get quantities of parts cast without waiting for the long lead-times and the high cost of automated high-pressure injection mold tooling. These types of molds are often the choice for pre-production molding, or production molding if the life of the project is in the thousands rather than the hundreds-of-thousands range and the cost of injection-mold tooling is prohibitive. The advantage of acrylic molds are the long mold life, parts can be cast from either silicone or polyurethane, very quick lead-time and cost effectiveness.

MATERIALS:

Silicones:
Silicone rubber, a synthetic polymer, has a strong silicon-oxygen chemical structure that gives the elastomer its unique performance properties. The process of vulcanization transforms this structure, allowing the silicon-oxygen polymer to become an elastic rubber which allows it to withstand a wide range of temperature extremes as needed.

Silicone rubbers have high tear and tensile strength, good elongation, great flexibility and a durometer range of 5 to 80 Shore A. Softer durometers are available as reinforced gels.

Silicones exceed all comparable materials in their insulating properties as well as flexibility in electrical applications. They are non-conductive and maintain dielectric strength in temperature extremes far higher or lower than conventional materials can handle.

Silicones can be formulated to comply with FDA, ISO and Tripartite biocompatibility guidelines for medical products. They are odorless and tasteless, do not support bacteria growth, and will not stain or corrode other materials. Most importantly, silicone rubbers exhibit superior compatibility with human tissue and body fluids.

Silicones resist water and many chemicals, including some acids, oxidizing chemicals, ammonia and isopropyl alcohol. However, silicones should not be used with concentrated acids, alkalines and solvents.

Polyurethane:
This category covers an extremely wide variation in physical and mechanical properties. Polyurethane polymers, produced by the reaction of polyisocyanates with polyester or polyether-based resins can be either thermoplastic or thermosetting. They have outstanding flex life, cut resistance, and abrasion resistance. Some formulations are as much as 20 times more resistant to abrasion than metals. It is a unique material that offers the elasticity of rubber combined with toughness and durability. Because urethane is available in a very broad hardness range it allows the engineer to replace rubber, plastic and metal with the ultimate in abrasion resistance and physical properties.