Polyurethane Casting Resins

Flexible, sustainable, abrasion-resistant, flame-retardant: the demands on models, moulds, tools, parts and prototypes are very high. The polyurethane resins from ebalta counter this with a high-performance and sustainable product range of tooling cast resins, elastomer and resins for vacuum casting, resins for RIM, polyurethane casting foams, electrical encapsulation resins and climbing holds resins for the production and manufacturing of pilot, small and medium series.

Due to their nature, polyurethane resins are ideal for shorter product life cycles and development times. Examples of this are ebalta’s machine casting compounds for rapid prototyping, rapid tooling and series production. Similar to thermoplastic materials (rubber, PE, PP, ABS, PC etc.), they perform very well due to their geometric flexibility, temperature resistance and high E-module.

PU resins can be used very well and easily for the production of large-volume parts, because they can easily be moulded. Since rapid changes in the production process can be made at any time with little effort, investment costs are low.

The many ways in which ebalta can develop the product sustainably make a strong argument for the use of PUR resins anyway: On the one hand, through the use of recycled polyols and renewable raw materials. On the other hand, due to the low weight compared to other materials. But also through material savings due to the high abrasion resistance. Therefore, new polyurethane developments from ebalta are available on request as a carbon-neutral product.

Tooling Cast Resins

Core box Model making Casting compounds

For decades, they have been a standard in model making and in mould and tool making: the hard and hard-elastic modeling casting resins and the filled and unfilled fast casting resins from ebalta. Properties such as fast, precise, eco-friendly and cost-effective characterise them, and at the same time they are easy and economical to process.

ebalta PU casting resins meet the individual requirements of models, core boxes and mould boards. When cast, they are highly abrasion-resistant and dimensionally accurate. Due to their low exotherm, they can be cast in very large volumes.

The ebalta modelling casting resins, such as the SG 130 fast casting resins or the GM 987 hard-elastic casting resins, are firmly established in mould making.

Elastomer Casting Resins

Impression Artificial Stitch with Elastomers

The ebalta PU elastomers were specially developed for high requirements in mould making and for the production of elastic parts in small series. Applications for polyurethane elastomers in mould making are, for example, in the tyre and concrete industries. In addition, PU elastomers are also used in scenery construction and for moulding artwork that require absolute attention to detail. Because of their high dimensional accuracy and good tear resistance, the elastic moulds are particularly well suited for this purpose. All ebalta elastomers as well as the vacuum resins can be used as casting resins for the vacuum process.

Furthermore, the ebalta elastomer casting resins are characterised by a high chemical resistance, low water absorption, good flow behaviour and good self-venting.

Resins for Vacuum Casting

Vacuum Casting Resin MG815 in Silicone Mould

Vacuum casting is the process of choice for parts with complex geometries. Prototypes and small quantities can be produced quickly, cost-effectively and to a high quality with the polyurethane machine casting resins from ebalta. The ebalta polyurethane resin systems are used to produce parts with properties similar to those of thermoplastic materials or elastomers. In addition, vacuum casting resins are also available with flame retardant properties according to UL 94 V0, or a classification according to DIN EN 45545-2: 2013-08 class R24 HL2 and RoHS compliant. The polyurethane machine casting resins have a high heat resistance and long pot lives.

All ebalta elastomers can also be used as vacuum casting resins.

ProductFlexural modulus MPaPDF
MG 703 / Z 4001340 ± 150
MG 707 / Z 4001500 ± 200
MG 804 / Comp. A+B2270 ± 150
MG 804 / MG 804-11975 ± 150
MG 804 GF / MG 804-14400 ± 400
MG 804, 804 GF / MG 804-12600 ± 150
MG 807 FR / Comp. A+B3700 ± 100
MG 815 / Comp. A + B2100 ± 200
MG 815 / MG 815 FR2770 ± 250

Resins for RIM

Casting resins for Rapid Injection Moulding (RIM) processes

With ebalta machine casting resins, high-quality, complex parts can be produced using the low-pressure RIM process (RIM: Reaction Injection Moulding). In this way, parts are produced in the RIM process within the shortest possible time. Short demoulding times also allow the production of small and medium-sized series.

In contrast to a thermoplastic injection mould, the RIM mould is less stressed. The polyurethane tooling boards ebaboard 1400 and PW 920 are highly suitable for fast RIM mould production.

A prime example of RIM resins is the MG 453 GF machine casting resin from ebalta (MG = machine casting resin, GF = glass fibre). It has proven itself in use for e-mobility in the automotive sector. The MG 453 GF resin is a high-performance, glass-filled RIM system that is characterised by a very quick curing time.

ProductFlexural modulus MPaPDF
MG 321 FR-S / Comp. A+B2000 ± 100
MG 331 FR / Comp. A+B2710 ± 100
MG 425 / PUR 191550 ± 150
MG 426 / Comp. A+B2185 ± 100
MG 453 / Comp. A+B1640 ± 50
MG 453 GF / Comp. A+B2510 ± 250

Polyurethane Casting Foam

Polyurethane foam for mould and tool making

ebalta polyurethane casting foams are usually used for moulding parts, as core material or for bases. The polyurethane foams are characterised by their very good surface structure and fluidity as well as their good heat resistance.

A true breakthrough in development is the flame-retardant polyurethane foam PU 60 FR. It can be found in insulation, multi-layer structures and lightweight panels and can be used in construction, the film industry and passenger transport as well as in hotels and renovation projects.

Due to its low density, the self-extinguishing casting foam can be used particularly well in applications where a low weight is required. The two-component polyurethane casting foam PU 60 FR is used to produce panels in sandwich construction. During processing, it starts foaming after only 20 seconds and has a pot life of 2-3 minutes. Demoulding is quick and easy after approx. 30 minutes.

Electrical Encapsulation

Casting compounds for electronics encapsulation

The PU electrical encapsulation resins from ebalta are used as encapsulation for electronic parts such as cable terminations, condensers, transformers or coils. They provide effective protection against the effects of moisture or dirt. Due to their distinct thermal and mechanical properties, ebalta polyurethane electrical encapsulants can also withstand stresses such as thermal cycling very well.

The product range also includes the filled, low-viscosity casting resin ebalta EGM-PU-21/30, formulated with non-abrasive fillers. It has been tested and approved according to UL Standard 94 flammability-test and the flame retardant is halogen-free.

Another example is the unfilled PU electro casting resin ebalta EGM-PU-02, which can be cast both in a vacuum and under normal pressure.

ProductShore hardnessPDF
EGM PU 0265 - 75
EGM PU 21-
EGM PU 21/3070 - 75

Climbing Holds Resins

Bunte Klettergriffe aus Polyurethan Gießmassen

The polyurethane casting resins from ebalta have all the properties that are necessary for a climbing hold:

  • They are highly abrasion-resistant so that the grip lasts for a long time.
  • Individual holds can be produced with a simple process.
  • On top of that, fancy colour pastes make for an appealing climbing experience.

Together with allHOLDS, a network of independent climbing hold manufacturers, ebalta has developed the material allHOLDS ECO-friendly Polyurethane. The eco-friendly PU casting material is offered as a carbon-neutral product for the entire product life cycle. More than 40 % renewable raw materials are used in the production process. The remaining emissions, which are produced until disposal, are offset by investments in appropriate offset projects. The material has many advantages over polyester in terms of sustainability and geometry. It can be cast by machine as well as by hand and is suitable for holds that comply with DIN EN 12572-3:2017.

As accessories, ebalta silicones are recommended for making the moulds for the climbing holds.

ProductGel time 200 g/20°C min.PDF
GM 1914 L / Comp. A + B8 - 10
GM 1914 S / Comp. A + B2 - 3