A process engineer orders two-component polyurethane and faces a choice: buy drums of components and cast in-house, or receive a finished part sized to specification. Self-casting without proper dosing, degassing, and temperature control produces voids and inconsistent hardness, and the node fails regardless. TIMOL cast polyurethane eliminates this issue: the customer receives a monolithic part with the specified hardness and service life. This article explains how a two-component system works, what properties it delivers in numbers, and how to order production in Ukraine to your own drawing.
What Two-Component Polyurethane Is and How It Is Cast
Two-component polyurethane is a system of two liquid ingredients — a polymer base and a hardener — mixed in a precise ratio and poured into a mould. During the reaction the mass polymerises and becomes a monolithic elastomer with the defined structure. It is exactly the controlled reaction of two components that allows hardness, elasticity, and wear resistance to be precisely set before casting.
The factory operates using the free-casting process. The components are dosed, degassed, and poured into an open or closed mould without high pressure, after which polymerisation proceeds at a controlled temperature. This method requires no expensive press tooling, making it suitable for both a single part to drawing and a production run. Geometry, wall thickness, and surface profile are determined by the mould itself.
The quality of a two-component part is determined by process discipline, not by formulation alone. The components must be conditioned to temperature, precisely dosed by mass, and degassed before pouring; otherwise air voids remain in the part body and hardness varies from batch to batch. This is why self-casting without the proper equipment gives unpredictable results, while factory casting with control at every step ensures consistent properties throughout the part.
A separate application is casting polyurethane onto a metal substrate. A shaft, roller, or drum is cleaned, degreased, and primed; polyurethane layer is then cast directly onto the metal. The result is a lined part where the metal carries the load and the polyurethane takes the abrasion and impact. The two-component system is particularly well suited here because adhesion to metal is set by the composition and primer before polymerisation. Typical products cast by this method are listed in the product catalogue.
Properties of Two-Component Cast Polyurethane
The key advantage of a two-component system is that the part’s properties are engineered by formulation, not delivered by chance. By adjusting the composition, the result ranges from soft and elastic to stiff and structural, while maintaining high wear resistance and chemical stability across the entire range.
Hardness is set in the range from 50 Shore A to 70 Shore D. Soft grades are used for shock absorbers, seals, pressure rollers, and dampers; hard grades for bushings, gears, scrapers, and wear-resistant guides. Abrasion per DIN 53516: cast polyurethane loses 38-39 mm³, while SBR rubber reaches 100-200 mm³. In practice this delivers a service life several times longer than standard rubber under the same operating conditions.
The operating range of -60…+100 °C covers most industrial conditions. The material is resistant to oils, petroleum products, dilute acids and alkalis; it does not absorb moisture and does not corrode. Tensile strength of 39-87 MPa exceeds that of most rubbers, and rebound elasticity of 34-61 % allows the part to recover its shape after each load cycle. Further detail on the material physics is available in the reference information section.
The practical conclusion for the process engineer is straightforward: the two-component system delivers one part for a specific task rather than a compromise between several stock grades. A soft formulation with high rebound is used for a shock absorber under impact load; a hard formulation with minimum abrasion for an abrasive scraper; an oil-resistant formulation for a seal in an oil-wetted environment. All of this is achieved from one casting process by changing only the composition and hardness, so there is no need to stock an assortment of dissimilar materials for each node.
Two-Component Polyurethane vs Rubber, Metal, and Plastics
A direct comparison shows why two-component cast polyurethane displaces rubber, metal, and rigid plastics alike. The table compiles reference data from standard tests for materials that compete in the same nodes.
| Material | Abrasion DIN 53516, mm³ | Operating t, °C | Hardness | Tensile strength, MPa | Density, g/cm³ |
|---|---|---|---|---|---|
| Polyurethane TIMOL | 38-39 | -60…+100 | 85A-95A | 39-87 | 1.05-1.25 |
| SBR rubber | 100-200 | -40…+80 | 40A - 80A | 8-20 | 0.94-1.1 |
| NBR rubber | 80-150 | -30…+100 | 40A - 90A | 10-25 | 1.0-1.3 |
| Capron PA6/PA66 | 30-90 | -40…+100 | 75D - 85D | 60-85 | 1.13-1.15 |
| Structural steel | n/a | -40…+500 | 120-250 HB | 370-700 | 7.7-7.9 |
Polyurethane has the lowest abrasion among elastomers while remaining lightweight: a density of 1.05-1.25 g/cm³ versus 7.7-7.9 for steel means the part is 6-7 times lighter. Capron is close on abrasion but its elasticity is only 5-15 %, so under impact it cracks where polyurethane recovers its shape. Rubber is elastic but wears several times faster and has lower tensile strength. The two-component system allows precisely the right point between these extremes to be set for the specific node.
Engineer’s tip: do not order a part simply by the terms “soft” or “hard” — specify the operating conditions. For impact load a slightly softer grade with high rebound is better; for abrasive sliding, a hard grade with minimum wear. And remember wall thickness: for lining, a thin layer on sharp abrasive wears through faster, so for heavy conditions specify a thickness reserve rather than relying on hardness alone.
Installation and Maintenance of Two-Component Parts
A finished cast part fits into most nodes without equipment modification. Solid bushings and rollers seat on shafts using standard fits; the lined layer runs directly on the original axis; seals and gaskets fit into existing grooves and flanges. This reduces the cost of transition to polyurethane, as re-engineering the node is usually more expensive than the part itself.
Maintenance is limited to cleaning off build-up and monitoring wear. Polyurethane does not absorb moisture, does not corrode, and is not susceptible to mould, so it requires no special care in the workshop. When the working layer of a lined part wears out, the metal substrate is not discarded: the old polyurethane is removed, the surface is re-prepared for adhesion, and a new layer is cast. The metal continues in service and the costs fall to the price of polymer and labour. This repairability is what makes two-component cast parts economically advantageous over the long term.
Where to Buy Two-Component Polyurethane in Ukraine
Two-component cast polyurethane in the form of finished parts can be ordered at TIMOL factory in Dnipro. Purchasing the components separately and casting in-house only makes sense when you have your own dosing and degassing equipment; otherwise hardness is inconsistent and voids remain in the part body. A finished product sized to specification eliminates these risks and immediately delivers predictable service life.
The factory produces parts from drawings, sketches, or worn samples and handles both single-unit orders and production runs. The free-casting process requires no expensive tooling, so a non-standard size presents no difficulty. Shipment is made throughout Ukraine, and Dnipro as a major transport hub simplifies logistics.
To get a calculation, supply the dimensions, required hardness, and a description of the node’s operating conditions. Engineers will select the formulation, estimate service life, and propose the optimal casting or lining option. For consultation and ordering, contact TIMOL factory.