Polyurethane Moulding Expertise

Our Polyurethane moulding facility offers a wide range of processes, to allow us to produce a vast range of products in small to medium volume for a huge range of industries. In conjunction with our In-house Tooling facilities, we offer a full development service from concept, through the design stages, to prototyping and finally, full production.

Polyurethane Foam Moulding

Martins has a wide range of Low Pressure moulding machines, supplied by of class leading manufacturers, operating in dedicated production cells meeting all the latest OEL requirements. A variety of material systems are employed, but essentially the moulding processes are all similar, in that an open or closed tool has a calibrated shot of material dispensed into it by the machine, which then catalyses and foams, expanding until it fills the mould and cures off. Cold Cure systems do not form a skin and so are elastic but quite fragile unless covered, Integral Skin systems sublimate a layer of solid material onto the walls of the mould which produces a skinned foam part, and Rigid systems foam to form a solid honeycomb structure which has excellent mechanical properties for a light weight material. General properties of these processes are as follows:-

Cold Cure Moulding

Cold Cure flexible foam offers the ability to manufacture a range of cushioning products. The absolute freedom of design permits the combination of attractive appearance and functionality when it is covered with fabric during or after moulding.

Advantages:

It can be produced in a range of densities and hardnesses, and may be combustion modified if required. As a reactive foam, it has excellent adhesive properties and costly and time consuming hand shaping is eliminated if you are substituting for a fabricated component.

Examples:

Low Density Moulding

Low density rigid foam is a lightweight material especially suitable for the structural reinforcement of vacuum formed panels and composite mouldings.

Advantages:

Examples:

Rigid Foam Mouldings

Rigid Foam is characterised by its distinctive sandwich construction, the compact outer skin and microporous core making it especially suitable for lightweight mouldings, with precise reproduction of the mould surface.

Advantages:

Using this material, prototype mould costs can be lower than thermoplastic injection tools, ideal for special items required only in small numbers.

Examples: 

Integral Skinned Mouldings (S-RIM – Soft Reactive Injection Moulding)

Integral Skinned Foam Mouldings comprise of a lightweight variable softness core graduating to a tough elastic skin, both originating from one foaming operation. It is of particular value in the Healthcare industry where the elimination of the seams found in overcovered upholstered items mean greatly improved hygiene as there is minimal opportunity for fungal or microbial growth in difficult to clean cavities.

Advantages:

Examples:

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Polyurethane Substrate Bonding

Martin’s Rubber offer an extensive polyurethane to substrate bonding capability, with the skills, knowledge and equipment to produce high quality bonded products with a variety of materials. We have the technical expertise and knowledge to ensure that we consistently produce high quality finished products that you can rely on. Whilst most substrates are metallic, we also bond to other substrates such wood, resin, Formica, and we incorporate threaded Inserts where required on Rigid mouldings to provide permanent fixings.

The choice of substrate rests with the component designer, who must consider the necessary strength and durability requirements in its use. Almost any material can be bonded to Polyurethane, provided that it can withstand the heat and pressure of the moulding process.

Polyurethane bonding can be successfully undertaken with many compounds and substances including:

If you have any requirements for polyurethane to substrate bondings, please speak to our Technical staff who can assist you with selecting the right material and substrate to meet your design requirements.

Polyurethane Solid Moulding

We also cast Solid Polyurethane parts, in hardnesses from 20° - 95°, including bonded rollers and tyres.

Micocellular Polyurethane

We machine Microcellular Polyurethane Foam to make high strength and resiliance components such as Bump Stops to fine tolerances, typically for Motorsport applications.

Finishing

We employ dedicated skilled finishers to ensure that your product is not only manufactured, but also trimmed, finished and packed to the excellence that we maintain throughout our manufacturing cells, meaning that there is a level of craftsmanship akin to the quality level you would expect.

From this section of our web site you can access details on our Polyurethane Products, detailed Technical Specifications, our Standard Polyurethane Products and more detail on the various Processes / Techniques available for the production of Polyurethane Mouldings. Please follow the links for further information.