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Polyurethane foam, often called PU foam, is a versatile polymer foam made by a chemical reaction between polyols and diisocyanates. It is lightweight, durable and highly customisable, making it one of the most widely used foams in the world.
Polyurethane foam is cost-effective and can be tailored to meet specific requirements. From furniture and bedding to automotive parts and insulation, it is found in many of the items we use every day.
| Flexible Polyurethane Foam | Rigid Polyurethane Foam | |
|---|---|---|
| Feel | Soft and elastic | Hard and dense |
| Structure | Flexible cell structure | Highly cross-linked, rigid structure |
| Typical uses | Furniture, mattresses, cushions, car seats | Insulation and structural applications |
Polyurethanes were first synthesised in the 1930s by Dr Otto Bayer and his team at IG Farben in Germany. Polyurethane foam began to be used commercially in the 1950s, and since then its use has expanded across many industries, from mattresses and furniture to insulation and packaging.
Among its early commercial uses was the automotive industry, where polyurethane foam offered a cost-effective, better-performing alternative to rubber in seat cushions, upholstery, insulation and soundproofing.
During the 1960s and 1970s, its use expanded into furniture and bedding, where manufacturers found it ideal for comfortable, durable mattresses and cushions. Memory foam was also developed in the 1960s, and memory foam mattresses later went on to transform the bedding industry.
Today, polyurethane foam is used in products ranging from insulation and packaging to sports equipment and medical devices, thanks to its light weight, durability and versatility.
One of the most significant innovations has been memory foam, which responds to heat and pressure, conforming to the shape of the body to provide comfort and support. It is now used in mattresses, pillows, seat cushions and medical products.
Polyurethane foam is made by a chemical reaction between polyols and diisocyanates. The polyols, diisocyanates and other ingredients are mixed under carefully controlled conditions, and the mixture is then poured into a mould or onto a conveyor, where it expands and hardens. The process can be adjusted to create foams with very different properties. See our guides to foam manufacturing and foam molding for more detail.
There are two main types of polyurethane foam: flexible and rigid.
The difference comes from the formulation: flexible foams are made with longer-chain polyols that produce a flexible structure, while rigid foams use shorter, more branched polyols and a higher proportion of diisocyanate, producing a highly cross-linked, rigid structure.
The properties of polyurethane foam can be customised by adjusting the formulation, including the type and ratio of polyols and diisocyanates, to create foams that are softer and more flexible or harder and more rigid.
Other additives can be included to give specific properties. For example, flame retardants can be added to make the foam more resistant to fire (such as the combustion modified foams used to meet UK furniture fire safety regulations), and colourants can be added to produce foams in different colours.
Polyurethane foam is used in furniture and bedding, automotive parts and construction, where it is used as an insulation material to reduce energy consumption and improve energy efficiency. See our foam applications guide for more examples.
Polyurethane foam is a key component in furniture and bedding, used to create comfortable, durable mattresses and upholstery cushions. Its use in these industries has grown significantly because of its comfort, versatility and value, and the development of memory foam has broadened its use further, from mattresses and pillows to seat cushions. See our guide to foam cushioning.
Polyurethane foam is used extensively in vehicles for seat cushions, upholstery and insulation, providing comfort and noise reduction. It is also used to make lightweight, durable car parts that can withstand the demanding conditions inside vehicles.
While polyurethane foam has many advantages, it also has a significant environmental impact. Its main raw materials, polyols and diisocyanates, are derived from petroleum, and the extraction and refining of petroleum and the production of these chemicals contribute to pollution and greenhouse gas emissions.
Polyurethane foam products can take a very long time to break down in landfill, and some additives, such as certain flame retardants, can leach into the soil and groundwater.
However, efforts are being made to improve recycling. Processes are now available that can break polyurethane foam down into its constituent parts so it can be reused, reducing waste and conserving resources. Our foam recycling guide explains how this works.
Because of its environmental impact, there is growing interest in alternatives, including natural materials such as latex and wool, as well as more environmentally friendly synthetic materials.
Natural latex, made from the sap of the rubber tree, is a renewable resource that is more biodegradable than polyurethane foam. Wool is also renewable and biodegradable, and offers excellent insulation.
Polyurethane foam is a lightweight, durable and versatile material that plays a vital role in furniture, bedding, vehicles and buildings. Its production and disposal do have an environmental impact, so it is important to keep exploring ways to reduce that impact through recycling and more sustainable alternatives, while continuing to benefit from what polyurethane foam does well.
Continue exploring foam types and properties across our technical glossary:
Whether you need replacement sofa cushions, seat pads or bespoke upholstery foam, the Foam & Covers team can help you choose the right polyurethane foam grade and cut it precisely to your measurements.
Contact Our Foam Specialists or Order Custom Cut Foam Online .
We make custom cushions and covers for settings of all kinds — Benches, Caravans, Windows Seats, Sofas and many more!