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Expert Urethane Casting Services for Low-Volume Prototypes & Parts

Transform your product concepts into reality with precision urethane casting. Perfect for bridge production and low-volume manufacturing, our vacuum casting services deliver injection-molded quality parts without the tooling costs. From functional prototypes to end-use components, we bring 25 years of manufacturing expertise to every cast urethane part, ensuring exceptional detail reproduction and material properties that meet your exact specifications.

Precision urethane casting process showing silicone mold and cast parts

Our Urethane Casting Services

Complete vacuum casting solutions from prototype to low-volume production, delivering injection-molded quality without the tooling investment.

Vacuum Casting

Precision vacuum casting process using silicone molds to produce high-quality urethane parts with excellent surface finish and dimensional accuracy. Ideal for creating multiple copies from a single master pattern with consistent results.

Prototype Fabrication

Rapid urethane prototype services for functional and cosmetic validation before committing to production tooling. We help you see and test your parts with injection-molded material properties at a fraction of the cost and time.

Material Selection

Expert guidance in selecting the right cast urethane resins to match your performance requirements. From rigid to flexible, transparent to opaque, we'll help you choose materials that simulate production-grade plastics perfectly.

Surface Finishing

Professional finishing services including painting, texture application, and custom surface treatments to achieve production-quality aesthetics. Our team ensures your cast parts meet both functional and cosmetic specifications.

Low-Volume Production

Bridge manufacturing solutions for quantities from 10 to 1000+ parts. Perfect for market testing, pilot runs, or ongoing production when injection molding volumes aren't justified. Fast turnaround with consistent quality.

Parts Qualification

Comprehensive testing and validation services to ensure your cast urethane parts meet performance specifications. We work with you to verify dimensional accuracy, material properties, and functional requirements before scaling production.

Service Process

Our Proven 5-Step Urethane Casting Process

Master Pattern Creation & Design Review

We begin by creating or refining your master pattern, typically using CNC machining or 3D printing. Our engineering team reviews the design for castability, suggesting modifications to optimize part quality, eliminate undercuts, and ensure proper draft angles for successful mold release.

Silicone Mold Fabrication

Vacuum Casting & Curing

Demolding & Post-Processing

Finishing & Quality Validation

Proven Excellence

Trusted by Industry Leaders

Delivering precision urethane casting solutions for leading brands across powersports, marine, medical devices, and consumer products industries.

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell
The Evok Difference

Why Choose Evok Polymers for Urethane Casting?

Over 25 years of manufacturing expertise combined with white-glove customer service and cutting-edge vacuum casting technology.

Manufacturing Expertise

25 years of experience in part design, prototyping, and manufacturing ensures your cast urethane parts are optimized for both form and function from the start.

Cost Transparency

We're upfront about all costs and help you make informed decisions about design modifications, material selection, and production quantities to maximize your investment.

Rapid Turnaround

Speed to market is critical. Our streamlined urethane casting process delivers high-quality parts in days, not weeks, keeping your development schedule on track.

Quality Assurance

Every cast part undergoes rigorous inspection with detailed documentation. We work hand-in-hand with you to ensure tolerances and specifications are met consistently.

Meet Our Casting Experts

Industry veterans dedicated to your manufacturing success.

Paul Dathe, Founder of Evok Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a passion for helping companies manufacture superior plastic parts at optimal prices. With over 25 years of specialized experience in engineering, product design, and solving complex manufacturing challenges, Paul brings unparalleled expertise to every urethane casting project. His background includes leading new product development at Caliber Products, where he launched 13 products and grew sales 540% through excellence in tooling, prototyping, and qualification processes. As a senior mechanical engineer at Entegris, Paul managed a $40 million product line for semiconductor applications, demonstrating his commitment to precision and quality. Paul holds four U.S. utility patents, is a Six Sigma black belt, and earned his Bachelor of Science in Mechanical Design from Bemidji State University with emphasis in rapid prototyping and 3D modeling. His deep industry knowledge, proprietary technology insights, and customer-first approach ensure your urethane casting projects receive expert guidance from concept through production.

Jason Weber

Industrial Designer

Jason Weber is a seasoned industrial designer who brings innovative thinking and functional excellence to every urethane casting project. His design philosophy is deeply influenced by his keen observation of human behavior and user needs, developed through his experiences in a multi-generational household. Jason excels at creating products that are not only aesthetically compelling but also highly functional and manufacturable. His expertise in translating design concepts into cast-ready specifications ensures that parts are optimized for the vacuum casting process from the initial stages. Jason's meticulous attention to detail and understanding of material behavior help clients avoid costly redesigns and achieve superior results. Whether working on cosmetic prototypes or functional end-use parts, Jason's creative problem-solving and collaborative approach make him an invaluable partner. In his spare time, Jason enjoys cooking, gaming, and unwinding, activities that fuel his creative energy and fresh perspective on design challenges.

Shawn Monitor, Sr. Industrial Designer at Evok Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn Monitor has been a vital creative and technical force in advanced product development for over two decades. His expertise in building complex mechanical and visual prototypes in various materials makes him exceptionally valuable for urethane casting projects requiring precise pre-production validation. Shawn is particularly adept at communicating evolving design concepts through physical prototypes and photorealistic renderings created in Otoy OctaneRender®. His involvement in pre-molding design reviews has significantly reduced risk in large-scale projects by identifying and solving mechanical challenges before tooling investment. Shawn's deep understanding of how parts behave in different materials and processes helps clients make informed decisions about cast urethane versus other manufacturing methods. He holds several patents and has conducted extensive research across diverse industries from consumer products to biotech and medical facilities. Shawn's ability to create prototypes that accurately predict production part performance, combined with his skills in Adobe Creative Cloud for technical documentation, makes him an essential resource for clients navigating the transition from prototype to production. Outside work, he practices photography and enjoys the Twin Cities live music scene.

Daniel D. Hoyt, Ph.D., Business Development Manager at Evok Polymers

Daniel D. Hoyt, Ph.D.

Business Development Manager

Dr. Daniel Hoyt brings a unique combination of technical expertise and strategic partnership development to Evok's urethane casting services. His Ph.D.-level understanding of system and process design, coupled with his passion for innovation and collaboration, helps clients navigate complex manufacturing decisions with confidence. Daniel leads initiatives that challenge traditional approaches to part design, prototyping, and manufacturing, always seeking methods that deliver better outcomes for customers. His vision extends beyond simply providing casting services—he's dedicated to building genuine partnerships centered on continuous improvement and mutual benefit. Daniel's expertise in Lean Partnership-Based Organizations empowers small and mid-sized businesses to compete effectively in their markets. As a skilled facilitator, public speaker, teacher, and coach, Daniel excels at helping clients understand how urethane casting fits into their overall product development strategy and business objectives. His talent for team building and mentorship ensures seamless collaboration across all project phases. Under Daniel's guidance, clients gain not just manufacturing services but a strategic partner committed to their long-term success and sustainable growth.

Frequently Asked Questions

How much does urethane casting cost?

Urethane casting costs typically range from $100-$500 per part depending on size, complexity, material selection, and quantity. Initial setup includes master pattern creation and silicone mold fabrication, but per-part costs decrease significantly with higher quantities. We provide transparent, detailed quotes that break down all costs so you can make informed decisions about your project.

What is urethane casting?

What is cast urethane?

What is a vacuum casting?

How long does the urethane casting process take?

What materials can be simulated with cast urethane?

How many parts can be produced from one silicone mold?

Is urethane casting suitable for functional testing?

Have More Questions About Urethane Casting?

Our manufacturing experts are ready to discuss your project requirements and help you determine if urethane casting is the right solution.

Certified Excellence

Awards and Recognition

Six Sigma Black Belt certification logo

Six Sigma Black Belt

Process optimization and quality assurance expertise

U.S. Patent and Trademark Office seal

U.S. Utility Patents

Innovation in manufacturing technology and processes

25 years experience badge

25+ Years Experience

Proven track record in precision manufacturing

Ready to Start Your Urethane Casting Project?

Get a detailed quote and expert consultation. Our team will review your design, recommend the best approach, and provide transparent pricing for your low-volume production needs.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 612-991-2001 You can also send us a quick email at