What Are Dual Durometer Polyurethanes?
Polyurethane products are known for their wide assortment of versatile properties, namely for their range of durometer, or degrees of hardness. This adjustability allows urethane products to suit a diverse range of applications whether a rigid or soft component is right for the job. While there are several standard formulations and durometers to choose from, what most people don’t know is that custom polyurethane products can also be prepared in multiple layers to allow for the use of different durometers in the same part. The resulting product is what we call a multi-layered polyurethane, or in some cases a dual durometer polyurethane. While sheets are the simplest dual durometer polyurethane products to produce, they are not the limit of PSI Urethane’s manufacturing capabilities; dual durometer formulations are also available for rollers, wheels, tubes, seals, bushings, and liners. The layers of polyurethane can encompass a vast range of material hardnesses. Let’s dive into what this means for customers whose operations can benefit from the use of multi-layered urethane parts.
What Dual Durometer Parts Are Used For
In most applications, multi-layered polyurethane parts take advantage of the unique ability to utilize two different durometers in a single component. This is especially common in cylindrical parts such as wheels and rollers which have a distinct core and outer wall. These parts, when produced by other manufacturers, are typically composed of a hard metal core with an outer coating of a soft material. When making the same part out of urethane, the core can be composed of a harder durometer (usually in the Shore D scale of hardness) and the outer layer can be made of a softer durometer urethane (around the Shore A scale) to achieve the same functionality as its traditionally manufactured counterpart. Customers can benefit from significant cost savings by consolidating production of a part like this to a single process in the same facility. Costs such as transportation between facilities and the cost of expensive metal cores are eliminated entirely by utilizing multi-layer urethane instead. The end product is cheaper to produce, lighter in weight, and reduces production lead time.
Another tool that can benefit from being produced by a dual durometer urethane is a cutting sheet. Rather than having a uniform composition throughout, a cutting surface can be made of a soft layer and a hard layer. The top layer which serves at the cutting surface can be made of a high durometer urethane to withstand daily wear and tear. The bottom layer can instead be made of a low durometer urethane to give the cutting sheet a grippy, non-slip property that will keep it in place while the cutting surface is being used. Spill control sheets operate on the same principle, where the soft side is used to create an airtight seal to protect a drain from being contaminated with spilled liquids. Similarly, bushings and seals can benefit from dual durometer formulations by having a rigid inner core designed for impact resistance and a flexible outer layer to maximize vibration and sound dampening.
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While the ability to produce a part with multiple durometers is a huge benefit of multi-layered urethanes, in some applications even the simple visual aspect of a multi-layered product can have its use. Urethanes with multiple layers of contrasting colors can serve as excellent wear indicators: as the outermost layer is worn away, the inner layer is revealed showing that it’s time to change out the part for a new one. This use of dual durometer material is especially preferred for use as a liner inside of blast chambers where the inner walls are frequently subjected to harsh abrasion. They can be used to the same effect in other high wear applications to indicate that a replacement liner will soon be required; operators can then accordingly account for ordering a replacement liner and planned down time during the replacement process.
Industries Using Dual Durometer Parts
With such an impressive array of possible applications, dual durometer urethanes are employed across a broad range of industries.
In process automation and packaging, dual durometer rollers convey units from point A to point B along production lines. A low durometer outer layer keeps product from slipping out of place on the line, while the high durometer core provides structure and rigidity to the roller. As mentioned previously, dual durometer rollers allow manufacturers to save on costs while producing a higher quality product with the same utility they expect.
Urethane parts provide outstanding performance in the automotive industry due to their high resistance to impact, abrasion, chemicals, and rot due to external forces. Nearly every rubber gasket, seal, or bushing on a vehicle can be replaced with a urethane version with a significant increase in performance. Bushings especially benefit from multi-layered formulations. When made with a high durometer core surrounded by a low durometer surface, urethane bushings can outperform OEM parts as vibration dampeners and noise reduction components.
Dual durometer urethane cutting mats are the perfect accessories to die cutting operations. Urethanes are self-healing materials which can be produced to meet tight tolerances, making them a highly preferred choice for precision die cutting. Urethane reduces wear on cutting tools by reducing the amount of pressure needed to cut material, and thereby significantly extends the life of both tools and dies. A low durometer backing allows for maximum adhesion to substrates while a medium to hard durometer outer layer makes for a cost-saving cutting surface.
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About PSI Urethanes
Since 1966, through our own independent research and activity in the Polyurethane Manufacturers Association, PSI Urethanes has stayed on the leading edge of urethane technology – including developing advances in new materials, comprehensive designs, and processing technologies. Today we are among the most respected and trusted suppliers of custom polyurethane products.
We operate from our 45,000-square-foot manufacturing facility in Austin, Texas, which houses an extensive stock of polyurethane products. Our fully equipped manufacturing facility includes a versatile range of processing machinery, which allows us to work on unique, one-of-a-kind projects, as well as high volume components. Our in-house engineering, tooling, and custom mold shop, produces custom and stock production orders with exceptionally fast turn-around times. From conception to prototyping, to final production runs, our technical representatives and design engineers will work closely with your staff to meet your critical tolerances and specifications. You are guaranteed to receive experienced, professional, and personalized service from the first contact through your on-time delivery, with complete confidentiality and dedication to protecting your good name.