Using a new tooling simulation software package has allowed a novel technique to be developed for the process of polyurethane casting using silicone rubber tooling. The manufacture of casting toolfaces is done in a wax material using a 3D Systems’ ThermoJet machine; this new technique has led to a significant reduction in the overall time required to produce polyurethane castings. Utilisation of the new tooling module for Magics™ RP from Materialise has enabled the creation of parting planes, material feed points, and location patterning, developing ideal models for reproduction in silicone rubber. This paper shows how the software is utilised for this purpose, and how the toolface design is established.