What You’ll Need

• “Polyform” – Polyurethane Casting Resin, Beige, Fast-Setting for Prototyping: Fast-setting resin ideal for rapid prototyping and small batch casting.
• “IWhite” – Polyurethane Casting Resin – White, Fast-Curing Two-Part System: Highly fluid, colourable resin suitable for intricate moulds and craft projects.
• “Be Flex” – Transparent Polyurethane Doming Resin – Scratch-Resistant: Provides a flexible, protective doming effect for labels and badges.
• “Prolux” – PU coating for tiles, concrete, plastic and metal – suitable for driveable surfaces: Hard-wearing coating for high-traffic floors or industrial surfaces.
• Clean silicone or plastic moulds (for casting projects)
• Mixing containers and stirrers (silicone or disposable)
• Protective gloves, eye protection, and (when handling uncured resin) a respiratory mask
• Disposable apron or old clothing
• Digital scales or graduated cups for accurate measurement

See Expanded Polyurethane Resin in Action

View real-world examples of casting, doming, and professional surface coatings created with polyurethane resin. These process photos demonstrate the clarity of domed badges, the detail achievable in model making, and the robust finish of high-traffic floors with polyurethane coatings.

Step 1: Prepare Your Workspace and Moulds

Always work in a well-ventilated environment and protect your surfaces with disposable coverings. Organise all your tools and lay out your personal protective equipment before handling any resin components. For casting or doming, ensure your silicone or plastic moulds are perfectly clean and dry, as any dust or moisture can cause defects in the final result. If using a surface like concrete or tiles, make sure it is thoroughly prepared as described on the particular product packaging.

Poor preparation can lead to resin not curing properly or sticking to the mould. Take your time on this stage for a consistent finish and easier demoulding or coating.

Step 2: Measure and Mix Resin Components

Expanded polyurethane resin typically comes as a two-part system (components A and B). Accurate ratios are crucial for even expansion and curing. Weigh or measure both parts precisely using digital scales or marked mixing cups in the ratio recommended on your product instructions.

“IWhite” – Polyurethane Casting Resin and “Polyform” – Polyurethane Casting Resin, Beige both require careful measurement for optimal results. Mix thoroughly but efficiently, scraping the sides and base of your mixing container, as these resins often begin curing rapidly (within minutes). Avoid introducing air bubbles by stirring smoothly, not vigorously.

Step 3: Pouring and Shaping the Resin

Once mixed, proceed to pour the resin without delay, as the chemical reaction and expansion begin almost immediately. Pour slowly to avoid trapping air. For castings, fill the mould gradually, allowing the resin to flow into all recesses. For coatings such as those applied with Prolux – PU coating, use a suitable spreader or roller and ensure the product is evenly distributed.

If working with doming resins like Be Flex, dispense the resin onto the centre of your label or badge and allow it to naturally self-level. Don’t move or adjust the piece until the resin has set to avoid disrupting the dome.

Step 4: Curing and Demoulding/Finishing

Allow sufficient time for the resin to expand and cure fully, following the timing specified for your chosen product. Conditions such as temperature and humidity will affect curing—warmer, drier environments are ideal. Premature unmoulding may damage the piece or leave a sticky surface, so patience is key. For coatings and doming, avoid heavy handling until the resin is fully set and robust.

After curing, sand any sharp edges if required (and if suitable for your application). Painted finishes may be applied to products such as “IWhite” for custom touches—ensure the resin is fully cured before painting or decorating.

Tips, Troubleshooting, and Common Mistakes

Do not rush the mixing or pouring process—this can introduce bubbles and cause uneven results. Always check product-specific guidance for mixing ratios and working temperatures. If the resin fails to cure or feels tacky, double-check that both parts were measured accurately and that the workspace temperature met the product’s requirements. Incomplete mixing or using containers with old residue can weaken your finished piece.

Store unused resin components in a cool, dry place with lids sealed tightly. Clean tools and surfaces immediately with appropriate solvents (following safety instructions) to prolong their reusability.

Close-Up: Professional Finishes with Polyurethane Resin

Detailed images of cured doming, surface protection, and intricate prototypes help visualise the versatility of expanded polyurethane resin. From glossy, flexible domes to perfectly cast miniatures and seamless driveable surfaces, polyurethane resin stands out for its reliability and finish.