Production of polyurethane foam products

Custom polyurethane foam product manufacturing — from concept to mass production

PC "Polymer-Complex" specialises in the production of polyurethane foam (PUF) products tailored to individual customer requirements.
We implement projects of any complexity — from selecting the optimal technology to organizing contract manufacturing. For clients without a ready-made sample, we create master models using 3D scanning and CNC milling.

Core competencies

More than 30 years of expertise in polymer engineering

Unique developments in polyurethane foam, molding technologies, and tooling design.
Own production facilities without limitations

We handle orders of any volume — from 100 pieces to 100,000 per month, ensuring flexibility and high quality.
Comprehensive approach

Our approach is not just about providing services, but building a partnership. We take care of every stage: from selecting raw materials for your products to organizing logistics all the way to your warehouse.

Range of materials and their applications

Rigid polyurethane foam

Rigid PU foam is highly effective as insulation for cold storage chambers and various facilities. It is also widely used in packaging, automotive manufacturing, furniture, and footwear production. Clients of Polymer-Komplex often use it to create decorative interior elements.

Flexible polyurethane foam

Flexible PU foam is a soft material similar to conventional foam rubber, but with a denser structure and high wear resistance. We use it to produce the following components:
— theater seats
— car seats
— ottomans
— upholstered furniture elements
— pipe cleaning rollers, and much more

Integral skin polyurethane foam

Integral PU foam products combine a lightweight, resilient core with a strong closed-cell outer shell. The integral skin has a leather-like appearance, feels pleasant to the touch, and offers excellent wear and chemical resistance. From integral PU foam, we manufacture the following components:
— tractor seats
— steering wheels
— armrests
— headrests
— waiting area chairs
— massagers, and much more

Viscoelastic polyurethane foam (memory foam)

A soft material with a memory effect. It is used for manufacturing:
— orthopedic pillows
— mattresses and toppers
— anti-decubitus cushions
— children’s toys
— souvenirs
— travel pillows, and much more

Examples

Project development stages for PU foam product manufacturing

To launch the project, we will need a drawing of your product or an existing prototype if you plan to reproduce a previously manufactured item.

Technical consultation

At this stage, online or offline meetings are held where we discuss the details of the product’s intended use, project implementation possibilities, and conduct preliminary economic calculations. If you are new to polyurethane foam technologies, we will provide detailed information about the characteristics of the components, their differences, and show examples of our previous projects that you can see in person. We will also carry out a test pouring of the components so you can observe the chemical reaction between components A and B.

Master model manufacturing
(prototype of the finished product)

To create a mold, a model is required — a physical object that fully matches the dimensions and texture of the final product.

Mold manufacturing

At this stage, the mold manufacturing process takes place, usually lasting 2 to 3 weeks. After completion, we perform a test casting to ensure the mold’s quality.

Mass production

Upon completion of mold development, we can offer continued cooperation. Our team of experienced operators will carry out the casting of polyurethane and PU foam products in the required quantities, with strict quality control to meet your specifications.

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