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Willsup Inc

Our capabilities: from concept to finished part

End-to-end polyurethane manufacturing under one roof. From mold design and material selection to casting, bonding, and delivery — with precision machining available in-house when your application requires it — we keep the process under one roof so you get faster iteration, tighter control, and parts built for demanding wear applications.

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What we can build and control in-house

Six core manufacturing capabilities let us handle custom wear parts, new product development, and replacement components without relying on outside shops for the critical steps.

  • Custom PU casting

    Open cast, compression, injection molding

  • In-house mold mfg.

    Designed & built in-house — timeline based on part complexity

  • Precision machining

    When required — up to 80″ diameter precision tolerances

  • Metal-to-PU bonding

    Steel, aluminum, stainless, sister company fab.

  • Rapid prototyping

    Drawing to prototype in days

  • Custom formulations

    Tailored shore hardness & chemistry

From your specs to your loading dock

A clear four-step workflow keeps communication fast and the manufacturing path predictable, whether you send a drawing, a worn sample, or performance requirements only.

  1. Share specs

    Send dimensions, drawings, worn parts, or operating conditions so we can define the application.

  2. Design mold

    We engineer the tooling and confirm geometry, tolerances, and material approach before production.

  3. Casting & finishing

    Parts are cast and bonded to spec. Many parts come out of the mold ready to use; precision machining is done in-house when the application requires it.

  4. QC & delivery

    Each run is checked before shipping so finished parts arrive ready for installation and use.

Polyurethane material specifications

A concise technical overview for engineers and buyers comparing polyurethane to common alternatives in wear, resilience, and operating range.

Typical polyurethane property range

Property Typical range
Shore hardness 60A–75D
Tensile 3,000–8,000 psi
Abrasion resistance Very high
Temp range -40°C to 80°C
Rebound Moderate to high

Comparison: polyurethane vs rubber vs steel vs UHMW

Material Abrasion Impact damping Noise reduction Weight
Polyurethane Excellent High High Medium
Rubber Moderate High High Low
Steel High Low Low High
UHMW Good Low Moderate Low

Have a wear problem? Send us your specs.

Whether you have a print, a failed part, or just a difficult application, we can recommend a polyurethane solution and the right manufacturing path.

  • Reverse engineering from worn parts
  • Material guidance for wear and impact conditions

Common questions about our capabilities

  • What shore hardness range do you offer?
    We cast polyurethane from 60A to 75D. Our team can recommend the right hardness based on your application, whether you need impact absorption, abrasion resistance, or a combination of both.
  • Can you reverse-engineer a worn part?
    Yes. Send us the worn part or a sample and we can measure, design the mold, and produce a replacement. We do this regularly for clients who need to replace discontinued or hard-to-source components.
  • What is the typical lead time for a new mold?
    Lead times depend on part complexity, mold geometry, and production volume. Share your specs with us and we will provide a realistic timeline for tooling design and manufacturing.