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Performance Highlights
Where to Apply
Flexible Polyurethane Molding System
Star Insta Mould
Flexible Polyurethane Molding System for Custom Casting
Star Insta Mould is a two-component flexible polyurethane molding system made from a liquid resin and hardener. Toolmakers, prototype workshops, and small manufacturers use it to cast rollers, stamps, and custom components without expensive metal tooling. Once mixed, the system is poured or injected into a mould and cures into a tough, flexible, or rigid part depending on the ratio used.
What sets this flexible polyurethane molding kit apart is its balance of fast demoulding, sharp detail reproduction, and repeated reusability, making it dependable wherever precision casting meets a tight schedule. It is a solid, dense casting system rather than a cellular material — unlike polyurethane foam molding, which produces lightweight, air-filled foam parts, Star Insta Mould is the better choice when the job calls for a dense, detailed, and durable moulded component.
Six Ways This Flexible Polyurethane Molding System Solves Your Casting Challenges
- Two-Component Polyurethane Formula — Resin and hardener mix in a simple ratio for consistent, repeatable curing.
- Pour or Inject Application — Suits open-mould casting as well as pressure injection for detailed parts.
- Flexible or Rigid Cure Options — Can be tuned to produce soft, bendable parts or firmer structural pieces.
- Fast, Reliable Demoulding — Cures into a stable, tack-free mould that releases cleanly without tearing.
- Sharp Detail Reproduction — Captures fine textures, undercuts, and intricate geometries with minimal shrinkage.
- Durable, Long-Life Moulds — Resists repeated flexing and abrasion, supporting multiple casting cycles from a single mould.
GET A FREE QUOTE
Talk to an expert.
Our technical team will assess your requirement, recommend the right solution, and send you a detailed quote — at no cost.
An ESCO recognized leader in the industry
Request your free quote
Fill in the form and we will be in touch within 24 hours.
Request received!
Our team will review your details and get back to you within 24 hours.
The Problem
Why a Reliable Moulding System Matters
Workshops that rely on rigid tooling or inconsistent casting compounds run into the same three problems again and again.
Cracking & Difficult Demoulding
Rigid mould materials often crack or distort when demoulding parts with undercuts, damaging both the tool and the finished casting, which drives up rework costs and delays production for busy workshops.
High Tooling Costs & Long Lead Times
Traditional metal or ceramic tooling takes weeks to machine and costs far more than short-run or prototype work can justify, slowing product development and inflating per-unit expenses across every batch produced.
Shrinkage & Loss of Casting Detail
Many casting compounds shrink unevenly or lose fine surface detail while curing, producing inconsistent parts that fail dimensional inspection and require costly secondary finishing before they are ready to ship.
Benefits
6 Ways This Flexible Polyurethane Molding System Solves Your Casting Challenges
Star Insta Mould is a two-component polyurethane moulding system designed for casting rollers, stamps, prototypes, and custom components. It offers fast demoulding, excellent detail reproduction, durability, and flexibility, making it ideal for precision casting and small-scale manufacturing.
Faster Turnaround on Every Batch
Because Star Insta Mould cures quickly at room temperature, workshops move from mixing to demoulding in a fraction of the time rigid tooling requires, letting teams turn around prototypes and small production runs without waiting weeks for machined tools.
Lower Tooling Investment
This flexible polyurethane molding system replaces expensive metal or ceramic tools with a simple resin-and-hardener kit, cutting upfront tooling costs dramatically and making short-run casting practical for workshops that cannot justify heavy capital spending on dies.
Consistent, Detailed Parts
Low shrinkage and smooth flow into fine features mean every cast component keeps sharp edges, textures, and undercuts intact, so parts pass dimensional checks the first time and reduce the need for secondary finishing or rework.
Longer-Lasting Moulds
The cured material resists tearing and abrasion through repeated flexing, so a single mould supports many casting cycles before it ever needs replacing, stretching material budgets further than rigid alternatives that crack after limited use.
Flexibility Across Applications
The same flexible polyurethane molding formulation adapts to both soft, bendable components and firmer structural parts, giving toolmakers one reliable system to cover rollers, stamps, gaskets, and rigid prototypes instead of stocking multiple specialised compounds.
Cleaner Demoulding, Less Waste
Because cured mould walls release parts without sticking or tearing, operators spend less time freeing castings and discard fewer damaged pieces, which keeps material waste low and protects the mould for its next casting cycle.
How to Apply
Method of Application
Applying Star Insta Mould is straightforward
Surface Preparation
Clean the mould thoroughly, remove any residue from previous casting cycles, and apply an even coat of release agent across all contact surfaces.
Mixing
Weigh the resin and hardener in the correct ratio, then mix them together thoroughly and at a steady pace, avoiding excess air entrapment, until the blend is uniform in colour and consistency.
Application
Pour or inject the mixed material into the mould promptly, before it begins to gel, then allow it to cure undisturbed for the recommended time before carefully demoulding the finished part.
Customer Stories
What Our Customers Say
FAQs
Frequently Asked Questions
Everything you need to know about Star Insta Mould.
What is Star Insta Mould used for?
Star Insta Mould is a flexible polyurethane molding system used to cast rollers, stamps, gaskets, prototypes, and other custom components that need fine detail and reliable release from the mould.
Is Star Insta Mould suitable for flexible parts only?
No. While it is best known as a flexible polyurethane molding compound, the resin-to-hardener ratio can be adjusted to produce parts ranging from soft and bendable to firm and rigid.
How long does it take to cure?
Cure time depends on the mix ratio, ambient temperature, and part thickness, but this flexible polyurethane molding system is formulated for a relatively fast gel and demould time compared to conventional casting compounds.
Can Star Insta Mould be used for foam parts?
Star Insta Mould is a solid, dense casting system rather than a foaming compound. If a lightweight, cellular part is needed, polyurethane foam molding, sometimes called pu foam molding, is the more suitable process.
What mixing ratio should I use?
The resin and hardener should always be weighed and mixed according to the ratio specified on the product's technical data sheet, since an incorrect ratio can affect cure time, hardness, and part quality.
Does it shrink after curing?
Like most flexible polyurethane molding compounds, Star Insta Mould is formulated for low shrinkage, helping cast parts hold accurate dimensions and fine surface detail after they cure.
What surfaces or materials can it be moulded against?
It can be poured or injected into silicone, metal, or other compatible mould materials, provided the mould is clean, dry, and treated with a suitable release agent beforehand.
How many times can a single mould be reused?
Because this flexible polyurethane molding system resists tearing and abrasion, a well-maintained mould can support multiple casting cycles before it needs to be replaced or refurbished.
What industries commonly use this product?
Toolmaking, automotive prototyping, printing and roller manufacturing, footwear, foundries, and art or décor casting are among the industries that rely on flexible polyurethane molding for custom parts.
How is Star Insta Mould different from ordinary casting resin?
Standard casting resins are often rigid and can crack during demoulding, whereas this flexible polyurethane molding formula is engineered to flex slightly during release, reducing damage to both the part and the mould.
Still have questions?
Our team is happy to help with technical specs, application guidance, or a custom quote.
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