Inventively different

PU Systems

The wide range of polyurethane (PU) parts we make is testimony to the wealth of different grades of raw material formulations available, each one providing specific benefits such as strength, density, flexibility and fire proofing.

We offer a range of PU systems including self-skinning, semi rigid, energy absorbent and structural foam. All of these can be produced by either open or closed tooling methods and can incorporate surface covering materials on the A surface, and hardware components on the B surface.

Foam in place – an innovative combination of two processes, which allows foam to be applied in a specific area of an otherwise rigid part. Ideal for vehicle components such as door armrests and centre console lids.

Soft foam – bespoke foam systems that can be tailored to OEMs’ Shore Hardness requirements, used to produce high volume insert mouldings and incorporated in door casing assemblies.

Backfilling – an exterior vinyl skin reinforced with PU and glass that can incorporate hidden fixings and/or B surface detail. When combined with a thin gauge vacuum formed skin, the PU process enables us to bring together the best characteristics of the materials used, including the colour and gloss of plastic and the strength of PU SRIM. An ideal combination for medium volume applications with a modest tooling budget.

Self-skinning foam – for use in grab handles and energy absorbent restraints. Parts made from this type of PU system have a tough, flexible skin over a softer foam core, making components that are strong, bendable and tear-resistant. Material is poured into a closed mould and can be colour matched through pigmentation or in mould painting. Where the tool surface is chemically etched it is possible to apply a texture or pattern to the skin surface. Inserts can be moulded into the part to provide a robust fixing solution.

PU over foaming – Where a metal insert or armature is located in the mould tool prior to the addition of the PU system it is possible to encapsulate the insert, providing even greater durability and strength.

In-mould painting – where required, we can incorporate an in-mould paint, which is applied to the tool surface before moulding. An ideal way to achieve custom colour parts, without the need to meet minimum order quantities.