Urethane Molding Process | Comcast Urethane

DFM Review

Geometry, process selection, and fit-for-purpose evaluated.

Tool Build

For Option A, Comcast Urethane works closely with a mold manufacturer in Marshall and manages the mold construction process from design to production parts. Tool ownership is customer-owned — the tool goes into production after payment is received. Or we run production from a mold you supply.

Formulation

Polyol system selected or custom-blended for target hardness, skin thickness, density, and service environment.

Mold & Cure

Meter-mix-inject or meter-mix-pour, demold, and post-cure to full properties.

Inspect & Ship

Dimensional and quality inspection.

Picking the right process

The first thing we decide.

Before we build a mold, we decide which process fits the part. Most of the time it's obvious, sometimes it isn't. Here's how we think about it:

Specify integral skin when...

User-contact surface mattersGrip, armrest, handle

Skin = finishNo paint or coating needed

SizeSmall to medium parts

FeelFirm surface + cushion interior

Specify RIM when...

Tolerances are tight±0.020 as molded

Surface is Class AAutomotive, consumer visible

Geometry is complexUndercuts, internal features

Volumes are higher> 5,000/yr typical

Specify flexible foam when...

Priority is cushioningSeating, positioning, impact

Surface feel isn't primaryUpholstered or covered

SizeAny — limited by mold

FirmnessTuned via IFD target

Specify pentane blowing when...

Cell structure mattersFiner cells than water-blown

Density consistencyTight batch-to-batch spec

Thermal performanceLower lambda required

Skin formationMore consistent integral skin

Typical timelines

How long does it take?

Prototype program

DFM review5 business days

First sample parts6–8 weeks (varies by size)

Stock-formulation pour3–5 days

Post-cure & inspection3 days

Typical total4–6 weeks

Production program

DFM & quote1 week

High-pressure machines3

Low-pressure machines5

Machine output range5 – 100 lbs / min

Pentane experience25+ years

Blowing agentsNon-ozone-depleting options

Mold temperatureTemperature-controlled molds

Mold arrangementsFlexible — single, gang, shuttle

Part weight rangeA few grams to 100+ lbs.

Pentane blowing roomState-of-the-art, Title V permitted

Production tool build6–8 weeks (varies by size and texturing)

Material qualification1–3 weeks

First-article inspectionPrior to production

Typical total6–12 weeks full production

Tooling options

Three ways to get to a mold.

We're flexible on where the tooling comes from. What matters is that the mold produces a good part — we'll tell you honestly if a customer-supplied tool has issues before we pour into it.

Option A — Comcast Urethane sourced tooling

You provideSTEP / IGES + 2D drawing

We deliverAluminum or steel tool via our Marshall mold partner

Prototype toolVaries by application

Production tool6–8 weeks (varies)

Tool ownershipCustomer-owned; tool goes to production after payment

Best forNew part development, full programs

Option B — You supply the mold

You provideCustomer-supplied production mold

We deliverCast parts, dimensional and quality inspection

Setup time1–2 weeks (mold qualification)

DFM reviewIncluded — we flag issues before pouring

Tool ownershipRemains yours throughout

Best forTransfer programs, second-source supply

Option C — We build from your part design

You providePhysical part or detailed sketch

We deliverReverse-engineered CAD + tool + parts

TimelineAdd 1–2 weeks for CAD generation

Best forLegacy parts, obsolete tooling replacement

What we need to start

PreferredSTEP + PDF with GD&T

Also acceptedIGES, Parasolid, SolidWorks native

MinimumSketch + dimensions + problem description

First stepDFM review, 5 business days

From your CAD to your receiving dock.