Flexible Foam Urethane

Molds for flexible urethane foam parts are created using laminated epoxy tooling. A pattern of the desired part is made by a skilled pattern maker. A parting line is established for the mold. The desired surface finish is applied to the pattern and set into the parting line. An epoxy surface coat is applied and several layers of laminate material are added until the mold achieves the appropriate thickness.

Once the epoxy has set up, the parting line is removed and the laminating process is repeated.  When the second half of the mold has set up it is demolded and the pattern is removed.  After an appropriate curing cycle and a surface sealant is applied, the mold is ready for production.  In the paint booth area the applicator heats the molds up to the specified temperature.  Then the applicator sprays 1-3 mils of in-mold coating paint onto the surface of the mold.

Establishing the parting line for an epoxy laminated fiberglass mold.

Demolding of a flexible urethane foam part from an epoxy laminated fiberglass mold.  The part is molded with a Ride Hyde finish.

For a more durable finish a Ride Hyde finish can be applied.  Once the Ride Hyde is cured the mold is then turned over to the molders.  There the molder inserts an armature (if required).  The armature uses precise pick-up points to attach to the mold.  The molder then finishes assembling the mold.  Once completed, the mold is charged with a specified amount of urethane foam by the molder. Once foam is cured, the molder de-molds the part and sends it onto the trim-post spray department. There the parts are trimmed of their flash and resprayed with urethane paint. In some instances an additional coat of a 2-part urethane is also applied for extra water and/or chemical resistance. This process can accommodate molded foam pads from 3/8” thick up to one foot and beyond. Nearly any density and feel can be achieved.

Parts Produced using Flexible Urethane Foam
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