Technical answers, no sales pitch.

A molded polyurethane foam with a dense, self-formed outer skin and a cellular foam core — in a single pour. The skin is chemically continuous with the core (not a separate laminated layer). The skin is tough and surface-finished; the core cushions. Common in ergonomic grips, armrests, medical housings, and equipment enclosures.

Conventional flexible foam has the same cell structure throughout. If you need a durable outer layer, you laminate or upholster a separate skin on top. Integral skin forms its own dense outer layer during molding — a single material, two zones, no secondary skinning step.

Reaction injection molding uses high-pressure impingement mixing (1,500–3,000 psi) and closed-mold injection. Cast urethane uses lower-pressure metering and open-pour gravity fill. RIM holds tighter tolerances, delivers Class A surface finish, and handles complex closed-mold geometry. Casting is better for large parts, low volumes, and parts that don't need closed-mold precision.

Pentane is a physical blowing agent — it expands into gas when heated, creating cellular structure in foam. Water (the alternative) reacts with isocyanate chemically to produce CO₂. Pentane-blown foams typically have finer cells, lower thermal conductivity, and more consistent density. The tradeoff: pentane is flammable, requires Title V air permits, and needs explosion-rated equipment. Comcast Urethane made the investment because the foam quality difference is meaningful in the parts we mold.

Our flexible foam runs from 6 to 16 lbs./cu.ft. at Shore A 30–60 durometer. IFD at 25% indentation ranges from 20 to 120 lbf depending on density and firmness tuning. Typical applications: cushions, medical positioning pads, anti-fatigue pads, and helmet liners.

Integral-skin thickness typically runs 0.030–0.120 inches. Skin hardness ranges Shore A 45–85 — softer for medical grips, firmer for industrial and automotive applications.

Yes. If you have an existing mold — whether from a previous supplier or built to your own tooling spec — we can qualify it and run production from it. We do a brief DFM review before the first pour to flag any issues with the tool. The mold stays your property throughout the relationship. This is a common path for transfer programs and second-source supply situations.

Yes, both. If you have a CAD file (STEP, IGES, or native SolidWorks), we'll have tooling built through our Marshall mold partner and return a DFM memo within 5 business days. If you only have a physical part or a detailed sketch, we can reverse-engineer the geometry, generate a CAD model, and build tooling from that — add one to two weeks to the normal timeline.

Yes. We mold around threaded studs, mounting plates, stainless bushings, and machined metal cores. The urethane flows into knurled or undercut features, creating a mechanical lock that's typically stronger than the urethane itself — no adhesive required.

We scale from low-volume pilots into tens of thousands on the same tooling.

Prototype program: 4–6 weeks from approved CAD to first-article parts. Full production program with custom formulation: 6–12 weeks.

Yes — pigment is added to the polyol before molding, so color is integral to the part, not a coating. Molded-in colors are UV-stable in aliphatic formulations and won't chip or wear off. Multi-tone effects and Pantone matching are supported.

ISO 9001:2015 certified. Michigan Title V air permit for pentane blowing operations.

Marshall, Michigan. All molding, finishing, and inspection happens at the Marshall facility. We ship throughout North America as standard and export to Europe and Asia-Pacific for qualified programs.

STEP, IGES, Parasolid, or native SolidWorks for 3D. PDF for 2D drawings with GD&T callouts. A sketch plus a problem description is enough for an initial conversation.

Yes — mutual NDAs are available by request for new programs. Customer-specific NDAs and MSAs supported when required.