Open-cell polyurethane foam molded to net shape. Density 6–16 lbs./cu.ft., Shore A 30–60 durometer, free-rise density 12–30 PCF — with firmness tuned to your application instead of cut from a bun.
Most flexible foam on the market is produced in large slabstock buns and then cut to shape. That works for commodity cushions — but it leaves you with CNC waste, exposed cut surfaces, and a dependence on someone else's stock density. Molded flexible foam pours the chemistry directly into your part's mold, forming a net-shape cushion with a naturally formed skin at every surface. Better dimensional control, less waste, and the ability to tune firmness to the cavity.
Flexible foam parts from Comcast Urethane aren't just cushion blanks. Our molded flexible foam can be specified with integral skin, textured or colored surfaces, and molded-in inserts — eliminating secondary operations and delivering a finished assembly directly from the mold.
When your application requires a tougher outer surface — for abrasion resistance, cleaner aesthetics, or handling durability — we mold a dense integral skin directly over the flexible foam core. No lamination, no glue line.
Surface texture and color are specified at the mold. Leather grain, fine stipple, custom patterns — replicated directly. Color is molded-in to a specified match, not painted. The finish doesn't wear off.
Threaded studs, mounting plates, and structural cores can be positioned in the mold before the pour. The urethane forms around them in one cycle — no secondary bonding or press-in step required.
Molded flexible foam with an integral skin is a maintenance-free surface — no fabric, vinyl, or leather to re-cover. The molded surface cleans easily and holds up to institutional use cycles without reupholstering.
Our foam quality starts with process infrastructure that most molders don't have — and 25+ years of experience using it.
Tell us the load and the feel. We'll formulate to hit both.
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