Cast Foam

Liquid level floats made from rigid foam

What is urethane foam casting?

Urethane foam casting is a process that starts with the making of a mold cavity. The cavity is made to the shape of the part you want to produce. The two most common methods of making a mold would be to machine the cavity or to cast a rubber mold around a “master” part. Once you have the mold, you are ready to cast a part from foam. The foam starts as two liquids that are mixed together and poured into a mold cavity. As the liquid chemicals react to each other they expand and fill the mold cavity. Once the foam has cured it is removed from the mold. This same mold can be used to make a large number of identical parts. There are a variety of different foams to choose from. Let us help you select the right one for your project.

Rigid Foam

With rigid foam we can create finished parts that have a hard, durable surface. At TS Industries we make a wide variety of liquid level sensors that are made from rigid foam. Our closed cell foams have a hard, smooth skin that holds up well in a wide variety of harsh environments. We have been able to provide solutions for many of our customers that were previously frustrated with finding an acceptable material for their float application.

Flexible Foam

Flexible foams are softer and usually have a rubber skin. Foam pads with a rubber outer skin, like those found on amusement rides, is a common example of flexible foam. Like rigid foams, flexible foams can be cast at a variety of different densities.

What are the benefits of working with cast foam?

Foxlok Canisters
Parts made from rigid foam. (Click image to view

First of all, if you are thinking of Styrofoam, stop. Even though cast foam is lightweight, it can be very strong with a hard surface finish that can hold up to a variety of applications. Here are just a few reasons you might choose cast foam for your application:

  • Light weight.
  • Strong.
  • Holds up well in many environments that other materials fail.
  • Low up-front mold cost.

Cast foam has a wide range of applications. Contact us to find out if cast foam is right for your project.

Find out if foam is the right material for your product.