A metal part that needs replacing every quarter due to corrosion, or a rubber roller that abrades in a few weeks on abrasive, stops the line at the worst possible moment. Cast polyurethane closes both problems: it wears several times more slowly than rubber and does not corrode like steel. This article covers what goes into manufacturing polyurethane products at TIMOL factory, how the material compares with its competitors in numbers, and how to order a part to your drawing.
What Cast Polyurethane Delivers Compared with Rubber and Steel
The primary reason for switching to polyurethane is node service life for the same part dimensions. The material combines the elasticity of rubber with the strength of plastic: it absorbs impacts and vibration while sustaining tensile loads up to 39-87 MPa, whereas standard rubber tears at 8-25 MPa. The operating temperature range of -60 to +100 °C means equipment with polyurethane parts operates reliably on open sites in both winter and summer.
Polyurethane does not corrode, is unaffected by fungus and mould, and holds petrol, technical oils, and most acids well. Hardness is adjustable over a wide range — from 50 Shore A to 70 Shore D — so the same part can be a soft damper or a hard wear-resistant element depending on the grade selected. This allows the material to be matched precisely to each node rather than accepting a compromise.
A further practical advantage is behaviour under impact. Polyurethane returns part of the impact energy elastically instead of transmitting it to the structure, so parts run quieter than metal ones and dampen vibration. In noisy production environments this noticeably reduces bearing and frame loads, and improves working conditions. The material has no sharp chemical odour and is safe for human contact, making it suitable for food-processing and packaging lines.
Polyurethane vs Rubber and Steel in Numbers
The easiest way to see the difference is on standard engineering parameters. The table below compares polyurethane with common SBR rubber and structural carbon steel, drawing on DIN 53516, ISO 37, and Matweb reference data.
| Parameter | Cast polyurethane | SBR rubber | Carbon steel (St3/St45) |
|---|---|---|---|
| Abrasion DIN 53516 | 38-39 mm³ | 100-200 mm³ | n/a |
| Operating temperature | -60 to +100 °C | -40 to +80 °C | -40 to +500 °C |
| Density | 1.05-1.25 g/cm³ | 0.94-1.1 g/cm³ | 7.7-7.9 g/cm³ |
| Tensile strength | 39-87 MPa | 8-20 MPa | 370-700 MPa |
| Hardness | 50 Shore A to 70 Shore D | 40-80 Shore A | 120-250 HB |
Reading the table: by DIN 53516 abrasion, polyurethane loses 38-39 mm³ versus 100-200 mm³ for SBR — rubber wears three to five times faster under identical conditions. Steel does not participate in this test as the method is designed for elastomers, hence n/a. For density, polyurethane is six to seven times lighter than steel: a part of the same size weighs noticeably less, which means less load on bearings, shafts, and structural supports.
Free-Casting Technology
TIMOL products are manufactured by free-casting liquid polyurethane into open and closed moulds. A liquid compound is poured into tooling, where it polymerises and reaches the specified hardness. This approach does not require expensive high-pressure press tools, so manufacturing individual parts and small batches to a specific drawing is economically viable.
Free casting offers a further advantage: freedom of geometry. A complex screen with conical perforation, a thick-walled wear plate, or a profiled roller can be cast without expensive tooling re-configuration. The finished part responds well to machining: it can be cut, turned, drilled, and ground to final dimension, so bearing seats come out accurate. Full details of the factory service range are in the services section.
Part hardness is set at the formulation-selection stage, so the same drawing can yield a soft or hard part simply by changing the grade — with no drawing modification. This is convenient when the same node needs to be trialled in two modes: a pilot sample is cast first, the wear pattern in actual service is assessed, then the grade is adjusted for the production batch. For parts bonded to a metal substrate, the surface is cleaned and degreased before casting so that the polyurethane layer holds firmly and does not delaminate under load.
Where Polyurethane Products Work
Cast TIMOL polyurethane operates across 12 industries, replacing quickly-wearing parts in each. In mining and metallurgy these are screening decks for vibrating screens, bunker and chute linings, and wear-resistant inserts. In agriculture and food processing, these are elevator buckets, scrapers, seals, and conveyor parts. In railway transport and ports, these are damping rings, fenders, and wear pads.
The factory catalogue covers bushings, rollers, wheels and tyres, scrapers, hydrocyclones, gravity equipment, screening decks, damping rings, seals, and other assemblies. The full range of standard products is in the product catalogue, and non-standard parts are cast to the customer’s size from a ready drawing or technical specification.
Engineer’s tip: before ordering a new part, send the factory a worn sample. From the wear pattern the technologist can determine what hardness actually works in your node and select the grade more accurately than from the drawing alone. This saves one iteration of material selection.
Installation, Lining, and Restoration
Polyurethane parts are installed with standard fasteners without special tooling: bolts, clamp strips, or shaft-press fits. Light weight simplifies installation of large wear plates and screening decks, and the elasticity of the material allows tyres and seals to be pressed on without risk of cracking. Maintenance consists of periodic visual wear inspection and checking fastener torque.
A separate area is restoration of worn assemblies by lining. The metal base with an eroded coating is sent to the factory, cleaned to bare metal, and a new polyurethane layer is cast. The restored assembly receives its original service life at a cost below that of a new complete assembly. This is particularly advantageous for large shafts, drums, and rollers where the metal core is still sound.
How to Order Manufacturing to Drawing
To start production, send the factory a drawing, sketch, or worn part, and describe the node operating conditions: load, temperature, the nature of the medium and abrasive. From this data the technologist selects the hardness, calculates the geometry, and gives the lead time. Reference material on polyurethane properties is in the information section.
TIMOL factory in Dnipro serves both standard catalogue items and fully bespoke parts. To obtain a consultation and calculation for your task, contact us via the contacts page. The more precisely you describe the node, the faster you will receive a ready solution that will operate several times longer than rubber or steel.