Cast polyurethane wheels, castors and rollers are made by pouring a two-component PU system onto a metal or plastic core. PU is chosen over rubber for higher load capacity, better wear and tear resistance, lower rolling resistance and non-marking treads. The tread is cast on a PU elastomer casting machine — we build the machine; you run your own or sourced PU system.
What You Need
- PU elastomer casting machine — meters and mixes polyol and isocyanate at fixed ratio and temperature
- Wheel/roller moulds — per diameter, width and profile
- PU system + core bonding primer — sourced by you
- Post-cure oven
The Process
- Core prep — degrease, shot-blast and prime the hub or shaft. Bond failure at the core is the most common defect.
- Conditioning — preheat mould; hold polyol and isocyanate at set temperature.
- Meter, mix, pour — machine doses both components at the fixed ratio; pour from the bottom to avoid air entrapment.
- Gel and demould at the set time.
- Post-cure in the oven to develop final properties.
- Machine to size — turn the tread to final diameter and profile.
Key Parameters
- Hardness — most industrial wheels and rollers are cast Shore A 75–95; printing/conveying rollers often softer, load wheels harder
- Ratio accuracy — decides hardness consistency part to part
- Material and mould temperature — controls flow, gel and surface finish
- Pot life vs pour time — must suit part volume and cavity count
- Post-cure schedule — under-cure means soft, fast-wearing tread
Which Machine
See our universal wheel casting machine and PU wheel dispensing machine, or the full PU elastomer casting machine range. For forklift-specific tooling see how to make forklift wheels.
FAQ
What hardness for PU wheels and rollers?
Typically Shore A 75–95. Softer treads grip and cushion; harder treads carry load and roll with less resistance. Your PU system and post-cure set the final value.
Can one machine cast wheels and rollers?
Yes. The same casting machine feeds different moulds, so wheels, castors and rollers are covered by changing tooling.
Do you supply the PU material?
No — we build the machine and can match moulds. You use your own or sourced PU system.
Tell us your part size, hardness and output — we will propose the right casting machine and quote.