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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.

Step-by-step urethane casting workflow showing mold creation to finished parts

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.

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

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

Matt Maskell
Matt Maskell

"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

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

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

Matt Maskell
Matt Maskell

"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

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"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

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

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

Matt Maskell
Matt Maskell

"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
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 and Chief Engineer at EVOK Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a singular mission: delivering the highest quality injection molded components at the lowest possible price through proprietary technology and deep industry expertise. With over 25 years specializing in engineering, product design, and solving complex injection molding challenges, Paul brings unparalleled depth to every project. He holds four U.S. utility patents and earned Six Sigma black belt certification, applying rigorous process optimization to mold design engineering. Prior to founding EVOK, Paul led new product development at Caliber Products, launching 13 products while growing sales 540% and expanding from 25 to 144 customers with 100% retention. His responsibilities spanned tooling design, functional assessments, 3D modeling, prototype fabrication, tolerance analysis, and mold flow studies. Earlier, as Senior Mechanical Engineer at Entegris, Paul managed a $40 million product line of ultra-clean liquid delivery systems for semiconductor applications. He began his career at Rollerblade in design and prototyping before serving in senior engineering roles at General Mills and Boston Scientific. Paul earned his Bachelor of Science in Mechanical Design from Bemidji State University with emphasis in rapid prototyping and 3D computer modeling. He's an active member of Allied Executives Business Leadership Peer group and the Institute of Packaging Professionals.

Jason Weber, Industrial Designer at EVOK Polymers

Jason Weber

Industrial Designer

Jason is a seasoned industrial designer with a passion for creating innovative and functional injection molded products. His design philosophy is deeply influenced by his life within a multi-generational household with his wife, two sons, and mother, which nurtures innate empathy and keen observation of human behavior—qualities that translate directly into user-centered design excellence. Jason brings creative vision to EVOK's engineering projects, balancing aesthetic refinement with manufacturing practicality. His ability to understand how people interact with products ensures that every component he designs not only meets technical specifications but also delivers intuitive functionality and ergonomic comfort. Jason's multidisciplinary approach bridges the gap between pure engineering and real-world application, helping clients create products that resonate with end users. Outside the studio, Jason finds inspiration through cooking, gaming, and relaxation, activities that fuel his creative process and problem-solving abilities.

Shawn Monitor, Sr. Industrial Designer at EVOK Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn Monitor has been an instrumental creative force on some of the most advanced injection molded seating and component projects of the last two decades. His particular expertise lies in graphically and physically communicating evolving design concepts and intricate part features through complex mechanical and visual prototypes built in diverse materials. Shawn creates photorealistic renderings using Otoy OctaneRender® and develops professional layouts, diagrams, and logos with Adobe Creative Cloud, providing clients with clear visualization of engineering concepts before tooling commitment. His deep involvement in pre-molding design reviews has significantly reduced risk on numerous large-scale projects by identifying and resolving potential manufacturing issues early in the development cycle. Shawn excels at finding mechanical molded part solutions that can be prototyped and validated prior to expensive production tooling, saving clients time and money while ensuring design intent is maintained. He holds several patents reflecting his innovative approach to injection mold component design. Beyond his professional achievements, Shawn practices photography and enjoys the vibrant Twin Cities live music scene, interests that sharpen his visual communication skills and creative thinking.

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

Daniel D. Hoyt, Ph.D.

Business Development Manager

Daniel brings exceptional expertise in system and process design engineering, coupled with strategic partnership cultivation that sets EVOK apart in the injection molding industry. His passion for innovation and collaboration drives initiatives that challenge traditional norms in part design, prototyping, tooling, and injection mold manufacturing. Daniel's vision extends beyond disruption—he's building a community centered on continuous improvement, mutual benefit, and genuine partnership that empowers small and mid-sized businesses to compete at the highest levels. His leadership focuses on creating Lean Partnership-Based Organizations that optimize engineering processes and deliver sustainable growth. Daniel's proficiency as a facilitator, public speaker, teacher, and coach, combined with exceptional team-building and mentorship abilities, accelerates EVOK's mission to transform industry standards. Under his guidance, EVOK establishes new benchmarks for collaborative engineering success, ensuring clients receive not just technical expertise but strategic insights that drive their competitive advantage in demanding markets.

Natalie Weber, Operations Officer at Evok Polymers

Natalie Weber

Operations Officer – LIV

Natalie is a dedicated apprentice in product design and management who embodies the harmonious blend of creativity and sustainability in injection mold engineering. Possessing innate curiosity and a discerning eye for innovation, she tirelessly explores where design converges with environmental consciousness—bringing fresh perspectives to material selection and dematerialization strategies. Immersed in intangible design principles since childhood, Natalie grasps the profound impact injection molded products can have on the planet, driving her commitment to infusing eco-consciousness into every project facet. Her education in sustainability, combined with hands-on mentorship from seasoned professionals, accelerates her mastery of product design intricacies. Natalie investigates diverse materials, manufacturing techniques, and emerging technologies, always evaluating their ecological footprint and lifecycle implications. Her journey extends beyond creating aesthetically pleasing components—she's shaping a future where injection mold design engineering seamlessly integrates sustainability principles, leaving a positive legacy for generations while meeting demanding performance specifications.

Julie Young, Accounting and Finance Manager at Evok Polymers

Julie Young

Accounting and Finance Manager

Julie Young has been an integral part of Evok since its inception, bringing meticulous attention to detail and thorough financial expertise to the organization. As an experienced accounting professional, she excels in organizing and categorizing transactions, reconciling accounts, and producing clear, concise financial reports that enable informed business decisions. Julie's proficiency in accounting software ensures streamlined processes and timely delivery of financial information, maintaining compliance with all regulatory requirements. Her dedication to professionalism and confidentiality provides the financial backbone that supports Evok's operations and growth. Beyond standard bookkeeping, Julie plays a critical role in vendor relationship management, ensuring all partners are paid promptly and maintaining the trust-based environment that is central to Evok's values. Her reliable financial services support both the team's effectiveness and customer satisfaction by ensuring resources are properly allocated to deliver exceptional injection molding solutions.

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.