High density PU foam block ideal for making sturdy patterns with precise surface detail and a high quality surface finish.
Our High Density Polyurethane Foam Block has a nominal density of 96kg/m³. Also available is our Low Density Polyurethane Foam Block with a nominal density of just 48kg/m³.
Perfect for large patterns and fast hand working:
- Can be cut and shaped by hand or machined.
- High density results in sturdy, durable patterns (which can be walked on).
- Dimensionally stable (will not expand or contract).
- Compatible with epoxy, polyester and vinylester resin systems.
- Can be finished to a high standard with a range of surface coats.
Marine Use / Core Material Use
As well as use as a pattern making foam block this High Density Polyurethane Foam Block is also intended for use (and approved for use) as a structural core material. Core materials can be used in GRP structures to increase stiffness for load bearing purposes, reducing weight, cost and laminating time.
Our High Density Polyurethane Foam Block carries Lloyds approval as a rigid core material for marine use making it also ideally suited for use as a composites core material in applications like boat decks and bulkheads where lightness, low resin uptake and cost are important factors.
Lloyds Registry of Shipping Approved Certificate of Acceptance No. YSL/SA/019 (for yachts up to 45' in length).
Our High Density Polyurethane Foam Block is available in block sizes of: 600x600mm, 600x1200mm and 1200x1200mm. Please choose the block size you require from the drop-down list.
Multiple blocks of foam can easily be bonded together to create very large patterns (full vehicle bodies, for example).
Using Polyurethane Foam in Patternmaking
Polyurethane foam like this is perfect for creating the main shape of a composites pattern.
For a comprehensive, step-by-step guide to composites patternmaking, including how to make, shape, coat and finish a pattern please watch our Video Guide to Composites Pattern Making by Hand.
For full technical specification please download the accompanying TDS.
||Upper Temp. Limit
||70°C for 7 days
||50°CC / 100% rh for 7days
||-20°C for 7 days
Transport and Delivery Information
This product is classified as safe for carriage to all destinations. No restrictions apply.
If this material is used as a core for the deck of a boat, will it absorb water if the outer laminate is damaged?
This PU foam is a 'closed cell' foam and so if the foam was exposed there would not really be any water uptake in the short to medium term. For example, if you submerged a block of this foam in water for a number of hours and then removed it, there would be almost no measureable water uptake.
If the damage was left unrepaired in the very long-term then water ingress into the damaged laminate along with pooled water in the damaged area would eventually start to deteriorate the foam and surrounding laminate so it is certainly advisable to repair any such damage correctly within a reasonable timeframe.
Is this foam ‘fire protection’ rated?
No, this foam is not rated for fire protection
Would this type of foam be suitable to make a gymnast's mushroom?
No, I don't think so. I'm not too familiar with the type of foam used for a gymnasts mushroom but I would expect it's a 'spongy' foam that would spring back into shape (more like what would be used in furniture padding) whereas this foam block, if dented, will stay dented (like the dry flower arranging foam Oasis).
Is this foam completely rigid, or could it be used as shock absorbing cushion?
It's completely rigid. If it is 'hit' it will dent and stay dented. The way to think of this type of foam that helps people the most is that it's similar to (albeit higher density and therefore stronger) Oasis - the type of foam used for dried flower arranging. Therefore, although it would absorb impact from a shock, it would deform and stay deformed.
If I machine this block to the shape I want, how do I seal it to make mouldings from? and what thickness do I need to add?
A layer of epoxy resin mixed with glass bubbles (to make it sandable) and some coloidal silica (to make it thick) makes a very good 'pattern coat' which once cured can be sanded and polished up to a gloss. Another option is to use polyester resin and glass tissue (to add some strength) and then spray the pattern with a 2 pack (2k) filler primer. Once fully cured the filler primer can be easily sanded and polished up to a gloss.
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