Castings Services

Met-L-Flo Additive Manufacturing Enabled Services

Casting is the perfect solution for a variety of problems you might be facing.                                         

For Example:

  • Castings in all Durometers (Shore 00, A, D)
  • Compatible with Electronic Applications
  • Create Small or Large Geometry Parts
  • Custom Production Finishes and Textures
  • Extreme Conditions (Dependent on Materials and Geometry)
    • High Heat Environments
    • Chemical Environments 
    • High-stress Environments
  • Production and Pre-Production Applications 
  • Show Ready Parts
Met-L-Flo works with a range of industries that utilize our Casting technologies including but not limited to:Custom Prototypes Chicago
  • Aerospace
  • Automotive
  • Agriculture
  • Consumer
  • Medical

      These examples show casting as an additive-enabled solution that offers our clients a wider range of solutions.  Because 3D printing is limited in material choices, casting is a great solution with a larger variety of options.  These solutions apply to all sizes and materials.

      The casting process is relatively simple. Casting starts by making a master or pattern. Once the master is finished, it is molded creating the cavity so that casting can begin.  This is repeated until the desired number of castings is produced.

      Castings can mimic practically any production material.  The Met-L-Flo team focuses on silicone, urethane, and foam castings. Nevertheless, we do offer a variety of durometers including shore 00, A, and D which provide a range of flexibility and durability. 


      • Elastomers
      • Epoxy
      • Foam
      • Silicones
      • Urethanes

      Castings are traditionally used in preproduction, custom prototypes, or low to high(100s)-volume manufacturing as production via bridge tooling. Additionally, secondary processes can be performed on castings for features like threaded inserts or two-shot molding for advanced application parts.  Or even full finishing like painting or plating or shielding to match your drawing call-outs.

      Types of tools 

      In the Casting process, a major component is mold, or tool, creation. This is not a metal tool as would be needed for large-volume production or injection molding. When we make molds we do not let them leave the facility. This allows us to ensure that the parts being produced from the molds are up to the highest quality standards. 

      Tools for Low Durometer Parts

      Rigid tools are generally made with Extrusion or PBF. These tools are made for molding soft parts. Because the part is flexible it can be removed from a hard tool. Whereas if a hard part was made in a hard tool it would be extremely difficult if not impossible to remove the part without damage. 

      To learn more about tools and the casting process check out our white paper.

      Mold and Pattern (Soft Tools)

      Mold and Pattern, Soft tools, and silicone molds are all in the same family of tools. These molds are used to make parts from a larger variety of materials because the mold itself is more flexible

      We consider a few things when choosing the process that best fits clients' needs; is it a showpiece or a functional piece and how complex is the geometry?

      We consider these things because it determines if a one-part or two-part mold is needed. One-part molds or book molds are used when materials allow or the timing is critical. Two-Part molds or box molds are used for RIM or dispensed materials as they may require it. 

      Rotational Molding 

      Rotational molding is a process that allows for hollow parts to be made. This process is generally used for making bottles, tubes, bladders, and other hollow parts. To learn more click here.

      Injection Molding

      Injection molding is a specialty process used for high-volume production. This process utilizes machines injecting material into a mold. To learn more about this process and its applications click here

      Over Molding

      Over molding is a process used for a range of applications. These would be compliant parts, threaded inserts, soft grips, or any time when more than one material is required. To learn more about this process and its applications click here.

      If you would like more information on castings take a look at our white paper called Expanding AM's Reach, Castings.

      If you are interested to see how our casting technology can assist you on your next project give us a call at (630)409-9860 or email us at 

      Have Questions?

      We're more than happy to address any questions or concerns that you may have.

      Contact Information

      Additional Information



      AS9100 Certified - ISO 9001:2015 Registered ITAR Certified