PU-GF-Filled AL
Reinforced grade
also PU + Glass Fiber/Microsphere Filler
AL = aluminium/metal-powder filled PU
Choose for metal-look, thermally conductive prototype tooling inserts and heat-sink-like mock-ups.
Values for the AL condition
Other PU-GF-Filled grades and fills
PU-GF-Filled is listed in 9 conditions; see the grade overview at PU-GF-Filled.
Compare all 9 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Mineral / talc-filled low-shrink casting grade | Lowest-cost filled option for bulky, non-load-bearing masters and models where shrinkage and cost dominate. | — | 42 | 2 | 86 Shore D |
Glass microsphere filled | Pick when isotropic shrinkage, easy machining/sanding and low density matter more than maximum stiffness. | — | 45 | 4 | 84 Shore D |
ALThis page Aluminium/metal-powder filled PU | Choose for metal-look, thermally conductive prototype tooling inserts and heat-sink-like mock-ups. | — | 45 | 1.5 | 88 Shore D |
Impact-modified (toughened) filled grade | Pick when snap-fits, living hinges or drop-test survival matter more than stiffness and HDT. | — | 45 | 14 | 80 Shore D |
Flame-retardant filled grade | Use for electrical enclosures, rail/aerospace interior mock-ups and any prototype that must pass a flammability check. | — | 50 | 2 | 86 Shore D |
15 wt% short glass fibre filled | Mid-stiffness option when parts have thin walls and full 30% fibre loading would make the mix too viscous to fill. | — | 55 | 3.5 | 85 Shore D |
GF30Default 30 wt% short glass fibre filled | Default reinforced vacuum-casting grade: best all-round stiffness/HDT/dimensional stability substitute for GF-filled ABS or PA housings. | — | 60 | 2.5 | 87 Shore D |
Heat-resistant glass-filled grade | Pick for under-hood, lamp-housing or paint-bake prototypes that must survive 120–150 °C after post-cure. | — | 65 | 1.5 | 88 Shore D |
40 wt% glass filled, high-stiffness grade | Use for maximum stiffness/lowest CTE jigs, fixtures and metal-replacement prototypes; brittle and hardest on tools. | — | 68 | 1.5 | 89 Shore D |
What is PU-GF-Filled AL?
PU-GF-Filled AL is PU-GF-Filled in the AL grade — choose for metal-look, thermally conductive prototype tooling inserts and heat-sink-like mock-ups. PU-GF-Filled AL has a tensile strength of 45 MPa (6.53 ksi), weaker than 52% of polyurethane grades. Elongation at break is 1.5% and the elastic modulus is 6 GPa (0.87 Msi). PU-GF-Filled AL has a density of 1.95 g/cm³ (0.0704 lb/in³), heavier than 105% of polyurethane grades. Its glass-transition temperature is 95°C (203 °F). GF30 is the default condition FabDigit quotes; AL is available on request or by drawing note.
Advantages
- Stiff — 6 GPa (0.87 Msi), better than 105% of polyurethane grades
- Conducts heat well — 0.9 W/m·K (0.52 BTU/hr·ft·°F), better than 105% of polyurethane grades
- Low moisture uptake — 0.2%, better than 100% of polyurethane grades
- Low, predictable mold shrinkage — 0.15%, better than 92% of polyurethane grades
- High service temperature — 100°C (212 °F), better than 90% of polyurethane grades
Limitations
- Heavy — 1.95 g/cm³ (0.0704 lb/in³), worse than 105% of polyurethane grades
- Limited ductility — 1.5%, worse than 100% of polyurethane grades
PU-GF-Filled AL properties
Typical room-temperature values for PU-GF-Filled AL; 13 are specific to this condition. Other listed values are PU-GF-Filled reference data and may not represent this condition. Bars are the position among polyurethane grades.
Physical4
PU-GF-Filled AL has a density of 1.95 g/cm³ (0.0704 lb/in³), heavier than 105% of polyurethane grades. Its glass-transition temperature is 95°C (203 °F).
Mechanical11
PU-GF-Filled AL has a tensile strength of 45 MPa (6.53 ksi), weaker than 52% of polyurethane grades. Elongation at break is 1.5% and the elastic modulus is 6 GPa (0.87 Msi).
Thermal10
PU-GF-Filled AL is rated for continuous service to 100°C (212 °F). It conducts heat at 0.9 W/m·K (0.52 BTU/hr·ft·°F), better than 105% of polyurethane grades. Thermal expansion is 38 µm/m·K (21.1 µin/in·°F).
Electrical7
PU-GF-Filled AL is an electrical insulator with a dielectric strength of 18 kV/mm (457.2 V/mil) and a resistivity of 1×10¹¹ Ω·m.
Chemical & Environmental3
Corrosion resistance is very good (80/100), better than 82% of polyurethane grades. UV resistance is poor.
Sustainability4
Producing a kilogram of PU-GF-Filled AL takes about 90 MJ of energy and emits 5 kg of CO₂ — less than 100% of polyurethane grades. Typical recycled content is 0%.
Manufacturability6
PU-GF-Filled AL's machinability is good (55/100, worse than 64% of polyurethane grades); weldability not recommended (5/100); formability not recommended (5/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with PU-GF-Filled AL
Is PU-GF-Filled easy to machine?
Machines and drills cleanly with sharp carbide or PCD tooling at high speed and light feed; glass filler is abrasive and dusty, so use vacuum extraction and expect fast HSS wear.
Can PU-GF-Filled be welded?
Thermoset — cannot be welded; join with 2K epoxy/PU adhesives, cyanoacrylate or self-tapping screws into cast bosses.
Can PU-GF-Filled be formed, bent or molded?
Gravity/vacuum cast into silicone moulds at 40–70 °C after vacuum de-gassing; filler settles, so stir immediately before pouring, keep pot life (2–5 min) in mind and post-cure 2–4 h at 70–80 °C for full HDT and low shrinkage.
What surface finishes work on PU-GF-Filled?
Sands and primes readily; fill pinholes, then use 2K PU or acrylic paint, soft-touch coatings or vacuum metallising — glass fibre can print through on high-gloss surfaces, so a filler-primer coat is recommended.
PU-GF-Filled chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| polyol (polyether/polyester polyol blendhydroxyl component; carries filler, catalyst, pigment | 30 – 50 | 40 |
| isocyanate (MDI/prepolymer, side B)aromatic MDI standard; aliphatic (HDI/IPDI) in UV grade | 25 – 40 | 30 |
| glass fiberchopped/milled E-glass in GF grades | 0 – 40 | 30 |
| glass microspheressolid or hollow beads in GF-MS grade instead of fibre | 0 – 30 | 0 |
| mineral filler (talc/CaCO3/aluminium powMIN and AL variants | 0 – 45 | 0 |
| additives (catalyst, pigment, defoamer, FR grade contains phosphorus/ATH flame retardants | 0.5 – 15 | 2 |
PU-GF-Filled AL — frequently asked
What is PU-GF-Filled AL used for?
PU-GF-Filled AL is typically used for structural jigs, stiff enclosures, dimensional master parts and load-bearing prototypes. In short: stiffest PU casting resin; lowest-shrinkage cast PU; glass-filled structural prototypes.
What is the tensile strength of PU-GF-Filled AL?
PU-GF-Filled AL has a typical tensile strength of 45 MPa (6.53 ksi) — weaker than 52% of polyurethane grades. Strength varies by condition: see the 9 listed tempers.
Is PU-GF-Filled AL easy to machine?
Reasonably — machinability is rated good (55/100, worse than 64% of polyurethane grades). Machines and drills cleanly with sharp carbide or PCD tooling at high speed and light feed; glass filler is abrasive and dusty, so use vacuum extraction and expect fast HSS wear.
Can PU-GF-Filled AL be welded?
Not readily — weldability is rated not recommended (5/100). Thermoset — cannot be welded; join with 2K epoxy/PU adhesives, cyanoacrylate or self-tapping screws into cast bosses.
What surface finishes work on PU-GF-Filled AL?
Sands and primes readily; fill pinholes, then use 2K PU or acrylic paint, soft-touch coatings or vacuum metallising — glass fibre can print through on high-gloss surfaces, so a filler-primer coat is recommended.
Can PU-GF-Filled AL be formed, bent or molded?
Gravity/vacuum cast into silicone moulds at 40–70 °C after vacuum de-gassing; filler settles, so stir immediately before pouring, keep pot life (2–5 min) in mind and post-cure 2–4 h at 70–80 °C for full HDT and low shrinkage.
What is the maximum service temperature of PU-GF-Filled AL?
PU-GF-Filled AL is rated for continuous use to about 100°C (212 °F), and briefly to 130°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
Sources
- UPX 8400 / PX 522HT filled polyurethane casting resins — Sika Axson (2022)
- RenCast / Renshape vacuum casting polyurethane systems — Huntsman Advanced Materials (2021)
- Hei-Cast 8400 series two-part urethane casting resins — Sanyu Rec / H&K (2020)
- Filled and glass-reinforced urethane casting systems — Innovative Polymers (2021)
- ISO 527 / ISO 178 / ISO 75 / ISO 868 plastics test methods — ISO (2019)
- Polyurethanes: Science, Technology, Markets and Trends — Wiley (2014)
Property data is compiled from published supplier and standards handbooks and normalised for comparison. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.