Casting Foam
Polytek® manufactures flexible and rigid polyurethane casting foams (PolyFoams) and a flexible, silicone foam (PlatSil® SiliFoam).
PolyFoam Series foams are two-part, self-skinning polyurethane systems that are used to cast lightweight rigid or flexible objects with densities in the range of 3 to 20 lb/ft³.
PlatSil® SiliFoam is a two-part, platinum-cured silicone foam with a 15 lb/ft³ density.
Learn more about each type of casting foam below:
PolyFoam Series foams are two-part, self-skinning polyurethane systems that are used to cast lightweight rigid or flexible objects with densities in the range of 3 to 20 lb/ft³.
Since these products are self-skinning, cast parts will capture full surface detail of the mold used. PolyFoam systems find numerous uses in commercial, industrial, hobby, craft, prop and display applications.
Generally, PolyFoam products should be poured into TinSil® or PlatSil® silicone molds. Barrier coats (e.g., primer paint) can be applied to silicone molds before casting foam in order to produce pre-primed parts right out of the mold. These foams can also be poured into Poly 74-Series & 75-Series polyurethane rubber molds that have been coated with PolyCoat Sealer & Release Agent.
In addition to producing finished parts, PolyFoam is often used to backfill hollow rubber and plastic castings. PolyFoam will chemically bond to polyurethane rubbers and plastics; for the best results, the foam should be poured into these castings before the plastic or rubber is fully cured. To bond PolyFoam to silicone rubber, a mechanical bond (e.g., cotton fibers) must be used.
Product Features
- Many easy 1A:1B mix ratios
- Self-skinning PolyFoam
- Rigid & flexible systems
- Cast parts with 3 to 20 lb/ft³ densities
- PolyFoams are practically odorless and do not contain toluene diisocyanate, MOCA, heavy metals or HCFCs
- Can be colored with PolyColor Dyes
Select a product below for additional product specifications and buying information.
Rigid PolyFoams
| Product | Mix Ratio | Free-Rise Density | Molded Density |
| PolyFoam R-2 | 1A:1B | 2.5 lb/ft³ | 4-8 lb/ft³ |
| PolyFoam R-5 | 1A:1B | 5 lb/ft³ | 8-20 lb/ft³ |
| PolyFoam R-8 | 1A:1B | 8 lb/ft³ | 8-20 lb/ft³ |
Flexible PolyFoams
| Product | Mix Ratio | Free-Rise Density | Molded Density |
| PolyFoam F-3 | 1A:2B | 3 lb/ft³ | 5-8 lb/ft³ |
| PolyFoam F-5 | 1A:1B | 5 lb/ft³ | 8-15 lb/ft³ |
| Color Dyes | PolyColor Dyes can be used to color PolyFoams. They are available in Black, Brown, Blue, Green, Red, Yellow, and a White Pigment. |
| PolyCoat Sealer & Release Agent | PolyCoat can be applied to polyurethane molds to cast PolyFoam without a release agent. It can also be applied to silicone molds to improve performance and extend their life. |
| Product Life Extender | Use PolyPurge Aerosol Dry Gas to extend the product life of PolyFoams by spraying it into containers before resealing. |
PlatSil® SiliFoam is a platinum-cured silicone foam with a 15 lb/ft³ density.
SiliFoam can be used for many applications, but is often used in conjunction with PlatSil® Gel Silicone Rubbers to create prosthetic appliances and props. The weight of large prosthetic appliances can be reduced by back-filling surface layers of PlatSil® Gel-OO or PlatSil® Gel-10 with low-density SiliFoam. SiliFoam will chemically bond to silicone rubbers, but should be poured against the silicone before the silicone has fully cured.
Select the product below for additional product specifications and buying information:
| Product | Mix Ratio | Free-Rise Density | Molded Density |
| PlatSil® SiliFoam | 1A:1B | 15 lb/ft³ | 15 lb/ft³ |
| Color Dyes | Silicone Color Pigments can be used to color PlatSil® SiliFoam. They are available in fleshtone, red, blue, green, yellow, black and white. |
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