| HS Code | 754054 |
| Material Type | Polyurethane tooling board |
| Color | Beige |
| Density | 1.15 g/cm³ |
| Hardness | Shore D 80 |
| Flexural Strength | 65 MPa |
| Compressive Strength | 85 MPa |
| Tensile Strength | 30 MPa |
| Coefficient Of Thermal Expansion | 45 x 10^-6 /°C |
| Thermal Conductivity | 0.30 W/m·K |
| Heat Deflection Temperature | 90 °C |
| Water Absorption | 0.3% |
| Maximum Service Temperature | 120 °C |
| Machinability | Excellent |
| Dimensional Stability | Excellent |
As an accredited 3D Systems RenShape 7810 factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
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In automotive styling studios, full-scale exterior master models and interior cockpit verification units are machined from laminated blocks of 3D Systems RenShape 7810 where the design freeze loop requires high edge definition and dimensional stability across a 1.0–1.5 m span. Block lamination is carried out with a two-component polyurethane adhesive applied at 200–400 g/m² and consolidated under a vacuum of 0.08–0.10 MPa for 12–24 h at 20–25°C; after adhesive cure, the blank is rough-milled with a 6 mm two-flute carbide end mill on a 5-axis gantry router equipped with an HSK-63 spindle running at 12,000–18,000 min⁻¹, with feed rates held between 3 m/min and 6 m/min and stepover limited to 0.3–0.6 mm to avoid cell tearing at butt-joined adhesive lines. A roughing allowance of 1.0–1.5 mm per surface is left before a 48 h conditioning dwell at 20±2°C and 50±5% RH, after which finish machining uses a 3–4 mm ball-nose tool with 0.2–0.4 mm stepover. The machined surface is then sealed with an epoxy tooling primer at 60–80 µm dry film thickness to reduce moisture absorption, filled with polyester filler, wet-sanded to 600–800 grit, and coated with a class-A inspection paint system before CMM validation. Dimensional checks are performed on a coordinate measuring machine verified to ISO 10360-2; acceptance is recorded against ISO 2768-1 class m or against the vehicle OEM digital reference under ASME Y14.5-2018, with surface deviations reported as colour maps. Terminal outputs include exterior body master models, interior cockpit modules, lighting housing mockups, and cubing fixtures for trim and gap inspection. The board is not specified for continuous service above the heat deflection temperature reported on the batch certificate under ISO 75-2 Method A, because elevated paint booth bake cycles can exceed the safe dimensional stability limit if thermal gradients are not managed with staged heating and fan-driven cooling.
Pattern equipment machined from RenShape 7810 is used in prototype and short-run sand casting of aluminium A356 and A319 alloys as well as grey iron components up to approximately 150 kg cast mass. In no-bake furan and phenolic urethane mould systems, the pattern face is subjected to ramming and compaction pressures of 0.4–0.7 MPa during moulding; the cellular surface must therefore be sealed with a two-component epoxy or polyurethane tooling sealer applied in 2–3 coats at 60–80 µm dry film thickness to prevent furfuryl alcohol or amine-water from migrating into the board and creating soft spots at the glue lines. Split patterns and core boxes require draft angles of 1.5°–3.0° on vertical draw surfaces, with a minimum of 0.5° on engraved text or grain features, while internal fillets are machined to 2–5 mm radius to reduce sand entrapment and strip resistance. Sand entry ports and blow tubes inserted into core boxes are lined with hardened steel or bronze sleeves because compressed air at 0.3–0.6 MPa carrying silica sand produces edge rounding in unsleeved polyurethane bores; published wear data for this specific configuration is limited, but production shops specify sleeves when batch quantity exceeds 200 cycles. Pattern boards are mounted on aluminium or steel draw plates with four-point lifting eyes, and the pull direction is verified with a dial indicator to keep pattern stripping axial rather than lateral. Castings produced from such patterns are inspected to ISO 8062-3 for dimensional tolerance and to internal foundry standards for surface finish; typical terminal components include intake manifolds, pump housings, sump casings, and one-off cylinder head cores. Because the board is not resistant to molten metal contact, it is used only as pattern equipment, and foundry bench exposure to strong solvents such as methylene chloride must be avoided to prevent surface swelling at sealed edges.
As heated sheet is drawn over the tool surface, the primary limitation is the heat deflection temperature recorded on the manufacturer batch certificate under ISO 75-2 Method A; continuous tool surface temperature is typically held at least 15–20°C below that value because local cell collapse and dimensional drift can occur when heated sheet contact is prolonged. For ABS sheet processed at 150–180°C, the tool body is temperature-controlled with water lines placed 25–40 mm behind the working face to maintain 55–75°C, and plug-assisted forming is preferred to shorten sheet-to-tool contact to 0.5–2.0 s. Vacuum holes are drilled at 0.6–1.0 mm diameter with 20–30 mm pitch in high-draw zones and 40–60 mm pitch in flat areas; hole edges are deburred with a 0.1–0.2 mm radius to avoid witness marks. Draw ratios are kept below 1.5:1 on unreinforced tool sections, and clamp-edge pressures above 0.10 MPa are not specified without an aluminium or steel support ring because the board can exhibit permanent compressive set under concentrated load. Polycarbonate sheet, which typically requires 120–140°C tool surface temperatures for acceptable finish, is excluded from continuous runs on this board unless the tool face is protected by a heat-resistant epoxy coating and contact is strictly intermittent; published data for direct PC thermoforming on this specific board is limited, so process qualification is required. Terminal products include ABS and HIPS equipment housing covers, packaging trays, and prototype interior panels where cycle counts are below 500 parts and dimensional tolerances do not exceed ±0.5 mm across the formed area.
| Substrate | Sheet temperature range | Tool surface target | Limiting mechanism |
|---|---|---|---|
| ABS | 150–180°C | 55–75°C | short contact 0.5–2.0 s |
| HIPS | 130–170°C | 50–70°C | low draw zones |
| PETG | 110–150°C | 45–65°C | witness mark control |
| PC | 160–200°C | not recommended for continuous runs | exceeds HDT threshold |
Because room-temperature composite tooling depends on low resin shrinkage at the master surface, the board is used as a master form for glass-fibre splash moulds rather than as a direct prepreg cure tool. The milled master is first sealed with an epoxy tooling gel coat applied at 0.5–0.8 mm wet film thickness, block-sanded in progressive stages from 120 grit to 600 grit, and polished with 3 µm diamond paste before a release film is applied. Female splash moulds are laminated against the master with epoxy or vinyl ester tooling resin reinforced with 1–3 plies of 300 g/m² chopped strand mat, and the lamination exotherm is limited to 45°C by controlling catalyst addition in the range 1.0–2.0 wt% for vinyl ester systems. The board itself is not introduced into autoclave cycles above 60°C unless the batch-specific heat deflection temperature supports the exposure; most aerospace prepreg cure cycles at 120–180°C exceed this boundary, so direct cure tooling is avoided and the master is employed only for room-temperature tool construction. Terminal outputs include composite cowls, wingtips, fairings, and prototype duct sections where the master geometry is transferred through a splash mould and the final component is checked against the CAD reference by optical scanning or CMM inspection. Dimensional confirmation follows ISO 2768-1 for non-critical surfaces and customer digital twin comparison for aerodynamic surfaces; when moisture uptake from ambient humidity creates surface distortion above 0.1 mm/m, the master is returned to 20±2°C and 50±5% RH for 48 h before further tooling work.
Once rough milling is completed and the plate is conditioned, checking fixtures milled from RenShape 7810 are constructed as lightweight modular plates for automotive interior and exterior components; plate thickness is typically 20–30 mm, and bushing bores are positioned with a positional tolerance of 0.05–0.10 mm under ASME Y14.5-2018. The board is stabilised before finish machining by rough milling to within 1.0 mm of final size, followed by conditioning at 20±2°C and 50±5% RH for 48 h, because residual stress from block lamination can produce measurable warping if this step is omitted. Aluminium or steel reference rails are bolted to the fixture frame because repeated clamping at 1.0–1.5 kN per point can cause local creep in unreinforced polyurethane; bronze or steel bushings are installed after reaming with 0.02–0.05 mm interference to maintain reference point retention. Thermal expansion along the longest axis is compensated by using the coefficient of linear thermal expansion reported under ISO 11359-2 and by maintaining the measurement room at 20±1°C; in shop-floor environments without thermal control, continuous temperature logging is required and measured deviations are subtracted from CMM data rather than relying on the board as a stable baseline. Terminal outputs include CMM fixture plates, optical scanning jigs, laser tracker reference frames for interior trim assemblies, and gap-and-flush inspection bodies used with production-representative checking pins. These fixtures are not recommended for high-humidity paint shop storage because moisture uptake above 60% RH can shift edge locations by more than the tolerance allowed for body-in-white coordinate checks.
When a silicone tool is cast against a milled master, the first process constraint is surface sealing, because uncured platinum-cure silicone can interact with residual moisture and open porosity in the board. The master is sealed with an epoxy primer applied at 60–80 µm dry film thickness, then finished to 600–800 grit to prevent surface defects from transferring to the silicone tool. A release agent compatible with platinum-cure RTV is applied before pouring silicone with Shore A hardness 25–40, and the silicone is degassed under −0.09 MPa vacuum before being cured at 25–40°C for 16–24 h. Because the silicone shrinks during cure and the board master undergoes small dimensional changes with ambient humidity, the CAD model is scaled by 0.3–0.5% only when the prototype part tolerance requires a net-shape silicone cavity; otherwise the master is cut to nominal and the polyurethane casting is measured to verify the shrinkage added by the vacuum-casting resin. Terminal products include short-series polyurethane housings for electrical connectors, medical device enclosures, and consumer electronics prototypes. The board is not specified for direct moulding against aggressive isocyanate systems without sealing, because unprotected exposure to liquid isocyanate can cause swelling at the working face and loss of edge geometry after the first 20–30 mould cycles.
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The product designated 3D Systems RenShape 7810 is a machinable rigid polyurethane tooling board supplied in cast slab form for styling models, master patterns, vacuum-forming tools, jigs, fixtures, and low-temperature composite lay-up tools. The manufacturer’s published datasheet lists a nominal density of 0.72 g/cm³ under ISO 1183-1, Shore D hardness of 72 under ISO 868, flexural strength of 30 MPa under ISO 178, compressive strength of 21 MPa under ISO 604, heat deflection temperature of 70 °C at 1.80 MPa under ISO 75-2, and coefficient of linear thermal expansion of 65 × 10⁻⁶ K⁻¹ under ISO 11359-2. The board is supplied in fine-celled off-white or cream slabs. Its principal difference from low-density polyurethane styling boards is a higher density and Shore D hardness, which improves edge retention and reduces sealant absorption. Its principal limitation relative to laminated epoxy tooling board is a lower heat deflection temperature and a higher thermal expansion coefficient.
| Property | Test method | Published datasheet value | Unit |
|---|---|---|---|
| Density | ISO 1183-1 | 0.72 | g/cm³ |
| Hardness | ISO 868 | 72 | Shore D |
| Flexural strength | ISO 178 | 30 | MPa |
| Flexural modulus | ISO 178 | 1200 | MPa |
| Compressive strength | ISO 604 | 21 | MPa |
| Heat deflection temperature at 1.80 MPa | ISO 75-2 | 70 | °C |
| Coefficient of linear thermal expansion | ISO 11359-2 | 65 × 10⁻⁶ | K⁻¹ |
| Water absorption at 24 h, 23 °C | ISO 62 | 0.4 | % |
The table values are manufacturer-typical values; lot-specific certificate-of-analysis data may differ. Before release into production, incoming blocks should be checked for density and Shore D against the lot certificate.
CNC machining of 3D Systems RenShape 7810 is normally performed on three-axis routers using carbide two-flute or three-flute end mills. Field data from polyurethane tooling-board machining indicate that edge chipping becomes measurable when tool runout exceeds 0.02 mm and when climb milling is replaced by conventional milling on finishing passes. On a production router with a 6 kW spindle and vacuum table, toolpath settings of 12,000 min⁻¹ spindle speed and 2,000 mm/min feed rate produce acceptable dimensional stability for boards up to 50 mm thick. At higher removal rates, local thermal accumulation softens the cut channel and can bond fine swarf to the groove wall. Chip extraction velocity below 20 m/s permits recirculation of heat-softened particles, producing surface smearing that is difficult to remove from deep recesses.
A tooling board tested to ISO 178 reports a single flexural value from a machined coupon, but production experience shows that the cast polyurethane slab is not fully isotropic. The skin of the slab may be slightly denser than the core, so flexural strength values taken from the as-cast surface can differ from values taken from a coupon machined from the mid-thickness region. This difference is most visible when a 50 mm-thick slab is machined into a deep-cavity vacuum tool: the cavity floor, located at mid-slab, may cut slightly more open-celled material and absorb more sealant than the as-cast face. Published data for this specific configuration is limited. When high reproducibility is required, a validation coupon should be machined from the same thickness zone as the final tool geometry and tested under ISO 178 before committing the full block.
Batch-to-batch variation in cell structure has also been reported to affect sealant absorption. A practical incoming control is to apply a 50 mm × 50 mm sealant patch on an off-cut from each incoming block, record the mass gain per unit area, and compare it against a previously qualified baseline. This procedure detects soft-cored or open-celled stock before contour finishing begins. In multi-block assemblies, failing to sort blocks by measured density can create visible seam-bond variation after primer application.
Before sealing or bonding, the machined surface should be deburred, vacuumed, and wiped with dry compressed air. For two-part epoxy or polyurethane sealers, light abrasion with P120–P180 grit improves mechanical anchoring. Contact with strong polar solvents such as methylene chloride, acetone, or methyl ethyl ketone should be avoided because these agents swell the polyurethane matrix and can induce dimensional relaxation. Amine-based epoxy hardeners should not be applied directly to unsealed RenShape 7810; residual free amines can attack the polyurethane surface and reduce adhesion. Where a hard epoxy surface coat is required, the board should first receive a compatible polyurethane sealer or an epoxy surface primer known to be free of reactive amine blooming.
With respect to moisture, boards should be conditioned at 23 ± 2 °C and 50 ± 5 % RH for at least 48 h before final finishing passes. Under ISO 62, water absorption after 24 h at 23 °C is published at 0.4 %, but prolonged storage at relative humidity above 60 % can raise surface moisture and produce primer hazing or delayed solvent release. When bulk moisture is suspected, pre-drying at 40 °C for 24 h is required before sealing. Drying should not exceed 50 °C because higher temperatures can accelerate dimensional creep and release residual casting stress.
For dimensional stability, the published coefficient of linear thermal expansion of 65 × 10⁻⁶ K⁻¹ means that a 500 mm gauge length changes by 0.65 mm across a 20 °C temperature shift. This is approximately three times the expansion of aluminium and five times that of carbon steel. Consequently, large jigs or inspection fixtures machined from this board require controlled ambient temperature during dimensional verification. For tolerance classes tighter than ISO 2768-m, ambient temperature should be maintained within ±2 °C of the temperature at which final gauging was performed.
Vacuum-forming tools fabricated from RenShape 7810 should be designed so that the surface temperature remains below the published heat deflection temperature of 70 °C at 1.80 MPa. Under repeated forming cycles above 55 °C, creep deformation becomes measurable in unsupported high-load areas such as edges, draw beads, and thin parting lines. Production-scale tools for ABS or HIPS have been operated with water-cooled aluminium backing plates to limit surface temperature to 55 °C or below. Unprotected exposure to polycarbonate sheet temperatures above 120 °C produces localized softening and permanent set. Published fatigue and creep data for RenShape 7810 under cyclic thermal loading is limited. When surface temperature is expected to exceed 55 °C for more than a few cycles, a coupon-level thermal cycle test should be run using the intended sheet temperature, contact time, and tool geometry rather than relying on static flexural strength or single-point heat deflection temperature.
Among polyurethane tooling boards, RenShape 7810 sits above low-density styling boards with published densities below 0.5 g/cm³ and published Shore D hardness below 60. That higher density improves screw retention for detachable fixtures and reduces edge rounding during hand finishing, but it also increases deadweight in large patterns. It is not equivalent to aluminium-filled or glass-fibre-filled epoxy tooling boards. Published data for epoxy tooling boards routinely list heat deflection temperatures above 150 °C and coefficients of linear thermal expansion below 30 × 10⁻⁶ K⁻¹. These differences exclude RenShape 7810 from autoclave cure tooling where thermoset prepregs are ramped above 120 °C. The selection boundary is therefore defined by thermal load: RenShape 7810 is appropriate for low-temperature pattern and fixture applications, while epoxy or metal tooling is required for high-temperature cure cycles and sustained compressive stress at elevated temperature.
