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Talking Technical

We pride ourselves on our backup, whether you buy from us direct or from one of our elite resellers

Being totally honest, we may not be able to answer every single question about rotacasting materials or techniques because it's a huge subject, but if we can't we usually know someone who can. That said, we design and build great rotacasters  because we do understand the casting process and have years of experience from working with our clients. We can often suggest techniques and approaches that may be helpful. We also like to put people in touch with people, because people are what business is all about.


So, if you have a question, please ask. 

So many casting materials to choose from

One of the greatest advantages of rotational cold casting is the wide choice of casting materials you can work with.

Our customers have used:

  • polyurethane

  • urethane rubber

  • silicone rubber

  • polyester resin

  • art & synthetic gypsum

  • metallised gel coats, chopped strand

  • quick setting concrete

Whether you're producing car parts, cosplay helmets, resin bronzes, prototypes, film props, replica dinosaur teeth, Romanesque urns, art toys, or replica limestone boulders, you'll have plenty of choice.

​You can call our rotacaster technical team on the number at the bottom of the page during normal working hours, whatever those are. People here often work all sorts of odd hours, but our office opening hours are between 9.00 a.m. and 5.00 p.m. GMT, Monday through Friday. Out of hours you can leave a message and someone will get back to you as soon as possible.   

If neither of these options suit you, you can also email our tech team.

Roocast silicone mannequin hand

Hand rotacast in-house using  ultra-soft silicone

Rotacast polyurethane plastic bottle prototype

Picking up the ink from a shampoo bottle cast (pigmented polyurethane cast)

Amazing results

Be careful what detail you put into your moulds, because you are liable to get out exactly what you put in - beware stray fingerprints! Depending on your mould construction, you could also be looking at casts that require little or no finishing.

Low mould costs

Moulds for rotational cold casting can be very inexpensive, unlike those for thermomoulding. The only real criteria for rotacasting moulds are that they holds their shape, don't leak, and you can clamp them securely to the rotacasting machine. Combine those three and you have a great mould! Moulds can be made from GRP (fibreglass), melamine, MDF and silicone, to mention but a few. If your heart is absolutely set on impact, you could even have a mould made from machined billet aluminium. They're a bit heavy though, and really not what you could call cheap.   

Rotocasting mouls can be cheap and easy to make

Moulds: best kept simple

Hollow rotacast castings can be back-filled or have cast in armatures

Polyurethane cast-in armature, back-filled with foam for lightweight density

Layer it up - the easy way

Try casting multiple skins in succession (our ControlCAST 2.0 makes this easy). Start with the expensive outer layer - the surface that impresses your customers. Then, if you need a hollow form, follow up with additional internal layers of something more cost-effective to build up strength and bulk. Alternatively, for a solid cast, back-fill with gypsum, high density foam, sand or even concrete to give you mass.


You can also rotacast armatures directly inside your mould. Getting a high quality finish to satisfy your customers whilst also keeping the bean counters happy is so satisfying.

Keep one eye on the power bill...

​There's little advantage in making savings on moulds and materials to please the bean counters if the machine you're using drinks electricity. Our sophisticated controls mean that Evolution RotaCasters (rotocasters) aren't the thirsty type when it comes to power. Every machine in the range also plugs into a standard, single-phase, 13amp wall socket. There is no need for three phase electricity or compressed air with one of our rotacasting machines.

Proven technology

Rotational casting machinery was first developed in the UK back in the 1950s, so rotacasters aren't exactly new technology. Doing it by hand (slush casting) has been around for countless centuries. All we've done is to bring the process and the rotacaster (rotocaster) machine right up to date, and to make it reliable and totally controllable so you get the right result, time after time. 

Free up your skills

Great skills take time and effort to build, making skilled hands expensive to hire and keep. Put your time and effort into creating the master and building the mould, not into running it. Once you have a mould and you've decided on the material and the running time, pretty much anyone can run an Evolution Rotacaster with minimal training. Clamp a mould to the turntable, fill, seal, shut the door behind you, press Run, then go and do something more interesting. 

Best of British

All of our rotacasters are designed and built by us in the UK by skilled engineers. Each one is built by hand, much like the finest cars in fact. We may just have missed a trick by not including that final little finishing detail from the best cars - a cup holder - but, we thought, why bother? You're going to be off doing something far more profitable and interesting than watching one of our beautiful rotacasters humming around in perfectly controlled circles all by itself as it gets on with its work, so your cup will probably be going wherever you do! 

You're in the right place for: rotacasters, rotacasting machines. rotocasting machines, rotocasters, rotational casting, rotational moulding, cold casting, slush casting, rotacasting, rotocasting, resin casting, resin moulding, silicone casting, silicon casting, polyurethane casting, hollow casting, made in the UK, and great British engineering
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