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Urethane Foam Molding

Urethane foam molding is a process used for products that need to have a soft, pliable finish. Using a polyurethane foam mold is different from other processes. During this process, a foamy solution is inserted into the form, along with the appropriate colorant or other materials, as needed. The resulting product is more flexible than a typical hard polyurethane product derived from other processes.

Foaming, or urethane foam molding, is the process of casting polyurethane foam. The material is mixed and placed in a closed mold to set up and expand during the polyurethane reaction. Density is determined by the weight of the material poured into the mold relative to the mold volume. (Density is typically measured in lbs/ft3 or kg/m3.)

Urethane foam molding uses flexible polyurethane foam as a cushion for a range of commercial products, such as commercial packaging, equipment parts, and automotive interiors.


  • The material itself is the main advantage. The need for flexibility in the end product is why this process is chosen.
  • The final product is made of high-performance, shock-absorbing, resilient polyurethane foam.


  • Possible cosmetic imperfections
  • Part details are difficult to achieve
  • Long cycle time