Hey I'm new to the forum and I'm looking some opinions on the design of one of the projects I've been working on. The part is a protective slider for an engine cover on a 2008 Yamaha R6 motorcycle. (see attached) I am fairly new to urethane casting so I would like to know if a design like this is doable, and if there are any problem areas that need to be changed in order to have it manufactured. The part will see operating temps up to 215deg F and needs to flex enough to absorb impacts (Protecting the stator cover when a rider drops the bike at low speed). The dimensions are 140.1×131.0×48.4mm. What changes would be recommended as far as design and material, and what should I expect to pay for an order of 50 units?
Thanks!

The shape would almost certainly dictate a 2 part mould minimum which increases the complexity.  Being quite a small and thin piece, even a toughened PU may not have significant strength to survive typical impacts without  breaking. Which may well be fine as it saves the casing.  You can help improve the strength by adding milled carbon fibre to the resin system you choose.  As to cost, it really would depend on the company doing the work so there is no easy way of working out the cost without approaching a company that does casting work like this.


Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Milled carbon fibre is a great additive to resins when you need improved tensile strength and mechanical performance.


Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

If I were going to attempt this it would be a two piece mold.

Urethane would be Task 21

Cured in a pressure pot.

To offset the TG I’d use aluminum/fiberglass tape or gold foil on the side that is exposed to heat.

Jason