Foam Moulding & Thermoforming
Intec Foams have the capabilities to mould PU foams with integral skins, Solid PU or Over Moulded foams, using chemicals specially formulated for the application. We can also take sheet foam and thermoform them by compression moulding, into intricate shapes.
Polyurethane is resistant to most chemicals and will retain its properties over a wide range of temperatures. As this uses a cold cure process, tooling is relatively inexpensive and the resin moulds can be easily modified during the proto-type stage.
Integral Skin Moulding
Integral skin PU foam moulding gives you a component with a tough, flexible skin that is moulded with a softer foam core.
Examples of applications:
- Armrests for cars
- Specialised seating
- Safety bars on theme park rides
- Handles
- Steering Wheels
- Headrests
- Gearshift Knobs
- Toys
- Furniture Components
PU Casting
This is the process where non-foaming elastomers of PU are used to create higher density and typically products with greater physical properties. These are widely used in a variety of engineering and construction application to produce products with good abrasion resistance and vibration damping properties.
Typical Uses:
- Floor mats
- Anti-vibration mounts
- Seals & Gaskets
- Applications that would be best suited to Injection Moulding but isn’t feasible.
Thermoforming PU Foams
The process involves pre-heating a sheet of a polyurethane foam material and then using a compression moulding technique, the foam is held under pressure at a predetermined temperature for a set time period; which we calculate until the foam takes a set.
After this period of time, the foam is removed from the press and trimmed down to the final shape/ profile.
Typical Uses:
- Floor panels in vehicles for acoustic applications
- Gaskets in loudspeakers
- Heat welding on edges
- Medical swabs
- Polish applicators with a logo
Rigid PU Moulding
A solid polyurethane foam used where light weight, good thermal insulation and impact energy absorption properties are required.
Typical Uses:
- Thermal Insulation Panels
- Pipeline Insulation & support systems
- Buoyancy Fillings
- Equipment Cases
Over moulding
Over moulding of a cheaper core material like a reconstituted foam or a closed cell polyethylene foam creates a product where the PU absorbs at lower frequencies and the core at higher frequencies.
Typical uses:
- Acoustic Floormats for Tractors
- Shock absorbers
- Seating products
Should you have a specific requirement or enquiry for these products or any other potential application, please give us a call for a friendly impartial discussion, or simply complete our online web form or email us at: info@intecfoams.co.uk and we will respond immediately.