The G series integral foam system was developed for the manufacturing of parts that seemingly combine two materials in a single product: a flexible spongy foam wrapped in a flexible, high-density skin.
- unique combination — achieved in a single casting process without the need for additional treatment or bonding layers.
- comfort and durability — designed to provide ergonomic comfort alongside high mechanical resistance.
- elastomeric memory — exceptional ability to return to the original shape after loading and kinetic energy absorption.
- perfect finish — the surface finish is precisely replicated from the mold, allowing for a vast array of textures.
Material and Technological Characteristics
The material is designed to provide ergonomic comfort alongside high mechanical resistance:
- elastomeric memory and energy absorption — G series castings excel in superior elastomeric memory after loading and kinetic energy absorption capacity.
- surface finish — the surface of the casting is replicated with maximum precision from the mold without the need for coating. This capability allows for a vast array of textures, including leather-like and other complex textures.
- skin thickness control — the skin thickness varies depending on the chemistry of the system and the production process, allowing the product to be matched to specific requirements for abrasion and tearing resistance.
- integration with casting inserts — during the casting process, inserts from other materials can be integrated, such as casting onto a metal, plastic, or wood skeleton. During polymerization, the polyurethane bonds chemically and mechanically, achieving an efficient, economical, and rapid process.
Common Applications
- transportation and automotive — coatings for steering wheels, dashboards, handles, bumpers, and seats for various vehicles (helicopters, trains, tractors).
- furniture and ergonomics — armrests and headrests, handles, and chair seats.
- medical equipment — flexible medical products and soft pads (e.g., eyepieces).
- industry and packaging — flexible packaging parts, flexible packaging, and energy-absorbent sheets.
Technical Specifications
| Feature | Technical Data |
| Chemical basis | Polyether – urethane |
| Cell structure | Open-cell core with high-density skin |
| Bulk density | 80 – 1100 kg/m³ |
| Tensile strength | 0.25 – 0.4 kg/cm² |
| Elongation at break | 30% – 120% |
| Skin thickness | Adjustable based on requirements |
| Elastomeric memory | Exceptional (returns to original shape) |
Logistical Benefits and Professional Support
- engineering advice — the company’s engineers recommend consulting with them in any specific case to utilize the full potential of the material.
- JIT supply — supporting a fast supply chain (Just In Time) to reduce inventory storage at the customer’s site.