Why does polyurethane outperform rubber for rollers and scraper blades?

Cast polyurethane abrades at 38-39 mm³ by DIN 53516; standard SBR rubber abrades at 100-200 mm³ — 2 to 5 times worse under identical conditions. Polyurethane also absorbs impact energy elastically, so scraper blades and roller liners hold their profile far longer in abrasive or impact-loaded applications.

Can TIMOL produce a single prototype part before series production?

Yes. TIMOL produces single-piece prototypes by drawing or sample. After prototype approval the same mold and compound go directly to series production without re-tooling. Confirm lead times via the contacts page.

Which polyurethane hardness is right for impact versus abrasive loading?

For abrasive sliding wear choose 80-95 Shore A (a hard yet resilient compound resists groove formation because it damps particle impact). For impact-dominant loads choose 60-70 Shore A (the softer compound absorbs the blow elastically, preventing cracking). When both conditions are present, TIMOL engineers select a mid-range compound and test it on a sample batch.

Do polyurethane parts require lubrication or special maintenance?

No special lubrication is required for most applications. Polyurethane has low surface friction against metals and does not corrode. For roller axle bearings standard grease intervals apply; the polyurethane layer itself needs no treatment. Clean with mild solvent or water if chemical contamination occurs.

How are polyurethane parts bonded to metal inserts during manufacturing?

The metal substrate is abrasive-blasted, degreased and primed with a bonding agent. Liquid polyurethane is then free-cast around the insert and cures under controlled temperature. Bond strength typically exceeds the tensile strength of the polyurethane layer itself, so the polyurethane wears before the bond fails.

Polyurethane Parts: Types, Properties and Industrial Applications

A scraper blade that lasts two weeks, a bushing that seizes on its first wet cycle, a steel liner that transfers every impact vibration straight to the frame — these are symptoms of the wrong material. Cast polyurethane parts from TIMOL address each failure mode: abrasion resistance 2 to 5 times better than rubber, elastic impact absorption that steel cannot provide, and the geometric freedom of free-cast molding to match any assembly.

Why Cast Polyurethane Beats Rubber, Steel and Polyamide

The comparison starts with DIN 53516 abrasion data. Cast polyurethane abrades at 38-39 mm³; SBR rubber at 100-200 mm³; NBR rubber at 80-150 mm³. Under identical abrasive conditions the rubber wears 2 to 5 times faster.

Polyamide (PA6/PA66) sits at 30-90 mm³ — competitive in dry sliding wear — but fails in wet or impact-loaded environments. Polyamide absorbs up to 8% moisture (dimensional change, loss of mechanical properties) and is brittle at temperatures below -30 °C. Cast polyurethane remains elastic to -60 °C.

Carbon steel handles temperature extremes but is seven times heavier than polyurethane, rusts without protective coating, and transmits every vibration directly to connected components. Polyurethane’s 34-61% rebound elasticity turns impact energy into elastic deformation rather than structural shock.

Comparison Table: Cast Polyurethane vs Alternative Materials

Material	DIN 53516 abrasion, mm³	Working temp, °C	Hardness	Tensile strength, MPa	Density, g/cm³
Cast polyurethane (TIMOL)	38-39	-60…+100	85A-95A	39-87	1.05-1.25
Rubber SBR	100-200	-40…+80	40A - 80A	8-20	0.94-1.10
Rubber NBR	80-150	-30…+100	40A - 90A	10-25	1.00-1.30
Polyamide PA6/PA66	30-90	-40…+100	75D - 85D	60-85	1.13-1.15
Carbon steel	—	-40…+500	120-250 HB	370-700	7.70-7.90

Engineer’s tip: hardness alone does not predict wear life. A 60 Shore D polyurethane roller absorbs lateral impact elastically; a polyamide roller of similar hardness (75-85D) develops microcracks at the same load. Before specifying hardness, define the primary failure mode: abrasive groove formation, impact cracking or chemical attack.

Types of Polyurethane Parts Manufactured at TIMOL

Rollers and conveyor rolls. Polyurethane shell bonded over steel core. Wear life three to five times longer than rubber-lined rollers in abrasive duty. The elastic shell grips product surfaces without marking and damps belt impact at loading zones.

Scraper blades and squeegees. Resist abrasion from slurries, ores, coal and bulk solids. Hardness range 70A - 65D matched to belt speed and material. No edge spalling under repeated impact.

Bushings and plain bearings. Self-lubricating in many applications. Operate in water, oil-contaminated environments and mild acids. Dimensional stability superior to nylon in wet conditions.

Shaft and roll linings. Free-cast polyurethane over prepared metal substrate. Working thickness 5-80 mm. Full bond at the metal interface; can be re-cast on worn shafts without replacing the metal core.

Liner plates and chute linings. Bolted or bonded to steel structures. Absorb impact from bulk material and reduce chute noise by up to 12 dB versus steel.

Screens and sieve panels. High open-area design with accurate aperture control. Flexible under vibration — apertures self-clear; no blinding. Life three to five times longer than woven wire in wet fine-screening duty.

Wheels and casters. Non-marking, silent-running, resistant to oils and mild chemicals. Hardness selected for floor load and surface protection requirements.

Custom profiles and seals. Any cross-section manufacturable by free casting. O-ring, lip seal, gasket, bumper, buffer — compound and hardness matched to medium, temperature and pressure.

Industries Served

Cast polyurethane parts serve 12 industries: mining and ore processing, metallurgy and foundries, mechanical engineering, oil and gas, rail transport, agriculture, ports and bulk handling, pulp and paper, food processing, printing, tube and pipe mills, and light industry. Browse the complete product range in the polyurethane product catalog. For individual service requirements see the services page.

Free Casting Technology: What It Means in Practice

Liquid polyurethane is poured at atmospheric pressure into a prepared mold. There are no press forces, so wall thickness can vary freely, metal inserts can be encapsulated, and undercut profiles are feasible without split-mold tooling. Part weight ranges from grams to hundreds of kilograms. Curing under controlled temperature gives consistent mechanical properties throughout the section.

This is how TIMOL produces single prototypes as economically as series parts — one mold serves both purposes. The same flexibility allows rapid design iterations without new tooling investment.

How to Order Polyurethane Parts from TIMOL

Prepare a drawing or worn sample, specify working conditions (temperature, load type, chemical environment) and required quantities. TIMOL engineers analyze the assembly, select the polymer compound and propose a geometry optimized for the application. Contact the TIMOL contacts page to submit a request or schedule a technical consultation.