Polyurethane Foam is cut and shaped by hand or, particularly the higher densities, by CNC router to produce dimensionally accurate patterns (or bucks) of a composite part. The filled nature of tooling block means that the shaped pattern can already have a high quality surface finish which needs little surface preparation before it can be used to produce a mould.
Lower density P.U. Foams are suitable for hand machining and even hand carving with the higher density model board being suitable only for hand machining or CNC machining. P.U. Model board is also used by architects and architectural model makers to create accurate, stable models of buildings or architectural landscapes. Once a pattern has been cut and finished to the desired shape the P.U. Foam is compatible with a wide range of finishes and release agents.
P.U. Foam is available in a comprehensive and standard range of boards for almost every application area in the design, modelling and tooling industries. Its formulation is to keep down weight and density but bring out the special physical values required for the application.
Design Models: Available for making design and styling models these boards are superior in terms of edge stability and surface structure. Furthermore they can be painted without much preparation (little to no filler) and are much more pleasant to machine due to their low dust emission.
Master & Copy Models: Suitable for making master models, it offers as excellent surface finish compared to other similar products. They are especially stable and keep their original form years later due to extensive post-curing process. This offers especially high compressive strength at a comparatively low density.
Fixtures & Gauges: Useful in the automotive industry for gauges and production jigs which render the desired properties concerning thermal expansion, stability and wear resistance for a cost effective solution.
Vac Form Tools: Special care should be given to the surface of vac forming tools to ensure that the part made has a smooth surface. For this reason, it is recommended that all surfaces are sanded down, sealed and, if required, covered with a release agent to ensure a good demould of the vac formed part. Polyurethane Designer boards are especially suitable for small series and prototype quantities.
Foundry Tools: For mid-range and pre-series production quantities cores and core boxes can be milled from polyurethane boards. This saves the traditional step of resin casting. According to empirical research these boards (1000 series) is able to withstand 10,000 shots at around 3 bar pressure.
Sheet Metal Forming Tools: Prototype press tooling, trial press tools, metal bending and hammer forming tools can be made quickly and economically using Polyurethane Designer Boards . Modifying the geometry of the tool is easily possible by cutting out the part of the tool to be changed, gluing in an insert and re-milling the contour. High compressive and flexural strength with good processing properties but also certain elasticity and the ability for the metal sheet to slide over the contours during pressing are important factors for sheet metal forming.