It depends on the hardness of the rubber, the material being cast and how consistently the release agent is applied. As a rough guide: a well-maintained Poly 74-45 mold can easily handle between 100 and 300 pours of polyurethane resin. Higher-hardness models such as PT Flex 60 or PT Flex 85 can exceed 500 pours under production conditions. For abrasive materials such as concrete or plaster, the number drops: expect between 30 and 80 pours before the mold starts to show surface wear.

The key to maximizing service life is to always apply release agent before each pour, store the mold protected from UV light and ozone, and avoid sharp bends that could cause cracks in the rubber.

They are two polyurethane resins with different applications. Feropur PR55+E55 is a rigid resin (Shore 75D) formulated for functional parts that need structural rigidity: tooling, mechanical prototypes, parts that will be machined or tapped. Its cure is somewhat slower, which allows you to fill complex geometries without the exotherm being an issue.

EasyFlo 120 is semi-rigid (Shore 65D) and has a very low viscosity that makes it ideal for rotocasting (hollow parts with thin walls) and for molds with narrow channels that Feropur would not flow through easily. It is also the choice when you need the part to absorb impacts or have some flex without breaking.

Jesmonite AC100 is a water-based acrylic resin system designed for architectural castings, interior coatings and decorative elements that must comply with fire reaction regulations (Euroclass B-s1,d0 classification). Unlike polyester or epoxy resins, it does not emit styrene or solvents during the process, which simplifies workshop ventilation.

It is commonly used for countertops, basins, interior facade panels, decorative sculptures and signage elements. It accepts marble, quartz, mica and specific pigment fillers to reproduce stone, cement, terrazzo or slate finishes with high fidelity. It can also be laminated with fiberglass to increase mechanical strength in thin-walled parts.

Yes. Polyurethane resins accept specific PU pigments, both in paste and powder form, which are mixed into component A (polyol) before adding component B (isocyanate). The typical percentage is between 1% and 3% by weight of the total mix — above that range, the pigment can interfere with the cure reaction and reduce the final mechanical strength.

Important: do not use epoxy or silicone pigments — each system has its own pigments formulated to be compatible with the chemistry of the material. For Jesmonite there are specific Pigmentos Jesmonite, which guarantee compatibility and long-term color stability.

For a prototype that needs to behave like a real plastic part — bearing loads, accepting threads, being machined or fitting together — the choice is Feropur PR55+E55. At Shore 75D it offers rigidity comparable to many engineering thermoplastics and can be machined with conventional tooling.

If the prototype needs to be hollow or thin-walled (to bring the weight closer to the final product), use EasyFlo 120 by rotocasting. For single-use prototypes or form-check purposes (not mechanical function verification), EXADURO plaster is the fastest and most economical option.