PU-Foam-Rigid
PU-Foam-Rigid is a two-component, self-skinning rigid polyurethane foam poured under vacuum into silicone or epoxy tools, available in density variants from D015 to D070 plus skin, flame-retardant and mineral-filled conditions (typical products: Axson F150, F160).
Reference datasheet — PU-Foam-Rigid is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the D030 condition
PU-Foam-Rigid grades and fills
PU-Foam-Rigid is supplied in 7 conditions, soft to hard. D030 is the default FabDigit quotes; the values on this page are for it.
Compare all 7 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Low-density rigid foam, ~0.15 g/cm³ | Pick when minimum weight or maximum fill volume matters and loads are essentially self-weight only (display models, void filling, insulating cores). | 2 | 3 | 30 Shore D | |
Flame-retardant rigid foam | Use for rail, aircraft-interior or enclosure mockups where a flammability rating is contractually required. | 6 | 3 | 48 Shore D | |
D030Default Standard rigid casting foam, ~0.30 g/cm³ | Default choice for lightweight mockups and large-volume parts where handling stiffness and machinability must both be adequate. | 6 | 4 | 45 Shore D | |
Self-skinning (integral-skin) rigid foam | Select when the as-cast surface must be paint-ready without extensive filling — dense skin over a light foam core. | 8 | 5 | 55 Shore D | |
Medium-high density rigid foam, ~0.50 g/cm³ | Use where the foam must take screws, inserts or fixture clamping and still be milled cleanly. | 12 | 5 | 58 Shore D | |
Dense structural / tooling foam, ~0.70 g/cm³ | Choose for machinable model-board-like blocks, load-bearing inserts and pattern work where near-solid stiffness is needed. | 18 | 6 | 68 Shore D | |
Mineral/glass-filled dense rigid foam | Choose for dimensionally stable pattern, jig and low-run mould blocks needing lower CTE and higher stiffness than neat foam. | 20 | 2 | 78 Shore D |
What is PU-Foam-Rigid?
PU-Foam-Rigid is a two-component, self-skinning rigid polyurethane foam poured under vacuum into silicone or epoxy tools, available in density variants from D015 to D070 plus skin, flame-retardant and mineral-filled conditions (typical products: Axson F150, F160). The default 0.3 g/cm³ grade reaches 6 MPa tensile strength, 4 % elongation, 0.18 GPa modulus, Shore D 45 and 0.07 W/m·K, with service to 85 °C, so it suits lightweight mockups, core inserts and insulation studies. It is a thermoset cellular material: not weldable, and the open core must be sealed before painting, with edge tear-out on the lowest densities. Choose a solid cast resin such as PU Cast or RPU where load-bearing strength is required. PU-Foam-Rigid has a density of 0.3 g/cm³ (0.0108 lb/in³), lighter than 100% of polyurethane grades. Its glass-transition temperature is 95°C (203 °F). PU-Foam-Rigid has a tensile strength of 6 MPa (0.87 ksi), weaker than 90% of polyurethane grades. Elongation at break is 4% and the elastic modulus is 0.18 GPa (0.0261 Msi).
What is PU-Foam-Rigid used for?
- Lightweight mockups
- Core/filler inserts
- Insulation prototypes
- Design models
Advantages
- Lightweight — 0.3 g/cm³ (0.0108 lb/in³), better than 100% of polyurethane grades
- Easy to machine — 88/100, better than 100% of polyurethane grades
Limitations
- Hard to polish — 20/100, worse than 97% of polyurethane grades
- Limited ductility — 4%, worse than 95% of polyurethane grades
- Poor heat conductor — 0.07 W/m·K (0.0404 BTU/hr·ft·°F), worse than 95% of polyurethane grades
- Absorbs moisture — dry before molding — 0.8%, worse than 88% of polyurethane grades
PU-Foam-Rigid properties
Typical room-temperature values for PU-Foam-Rigid-D030; bars are the position among polyurethane grades.
Physical4
PU-Foam-Rigid has a density of 0.3 g/cm³ (0.0108 lb/in³), lighter than 100% of polyurethane grades. Its glass-transition temperature is 95°C (203 °F).
Mechanical11
PU-Foam-Rigid has a tensile strength of 6 MPa (0.87 ksi), weaker than 90% of polyurethane grades. Elongation at break is 4% and the elastic modulus is 0.18 GPa (0.0261 Msi).
Thermal10
PU-Foam-Rigid is rated for continuous service to 85°C (185 °F). It conducts heat at 0.07 W/m·K (0.0404 BTU/hr·ft·°F), worse than 95% of polyurethane grades. Thermal expansion is 70 µm/m·K (38.9 µin/in·°F).
Electrical4
PU-Foam-Rigid has an electrical resistivity of 1×10¹¹ Ω·m.
Chemical & Environmental2
UV resistance is poor.
Sustainability4
Producing a kilogram of PU-Foam-Rigid takes about 103 MJ of energy and emits 4.6 kg of CO₂ — less than 62% of polyurethane grades. Typical recycled content is 0%.
Manufacturability5
PU-Foam-Rigid's machinability is excellent (88/100, better than 100% of polyurethane grades); formability not recommended (5/100).
Common Calculations4
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the polyurethane family
Yield strength against density for every polyurethane grade FabDigit runs. PU-Foam-Rigid is highlighted; hover a dot for its name, or open the interactive family chart.
Working with PU-Foam-Rigid
Is PU-Foam-Rigid easy to machine?
Cuts and mills very easily with sharp single-flute or foam-specific tooling at high rpm/low feed; use vacuum extraction — the dust is fine and irritant — and expect cell tear-out on thin edges of low-density grades.
Can PU-Foam-Rigid be welded?
Thermoset and cellular: not weldable; join with PU/epoxy adhesives, dowels or embedded inserts potted in place.
Can PU-Foam-Rigid be formed, bent or molded?
Two-component pour under vacuum into silicone or epoxy tools at 25–40 °C mould temperature; meter accurately, degas, and control shot weight/vent layout since density and skin quality depend on constrained rise (demould typically 20–60 min).
PU-Foam-Rigid chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| polymeric MDI (diphenylmethane diisocyanisocyanate side | 40 – 60 | 50 |
| blowing agent (water / HFO / pentane)defines cell structure and density | 0.5 – 4 | 2 |
| amine + tin catalyst package | 0.3 – 2 | 1 |
| mineral / glass filler (filled grades on0 in the default unfilled foam | 0 – 40 | 0 |
| flame retardant (phosphate ester, FR gra | 0 – 15 | 0 |
| polyether/polyester polyol blend — compocontains catalysts, silicone surfactant, chain extenders | ≥ 35 (balance) |
What surface finishes work on PU-Foam-Rigid?
Skin sands well but the open core must be sealed with polyester filler or a 2K PU primer before painting; no plating, and UV exposure needs a pigmented/clear-coated topcoat to prevent yellowing.
Equivalent designations
Standards and trade names that resolve to PU-Foam-Rigid in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- Also called
- Rigid Foam PU Resin
How much does PU-Foam-Rigid cost?
PU-Foam-Rigid is a premium-cost polyurethane ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
PU-Foam-Rigid — frequently asked
What is PU-Foam-Rigid used for?
PU-Foam-Rigid is typically used for lightweight mockups, core/filler inserts, insulation prototypes and design models. In short: lightest vacuum-cast PU; self-skinning foam system; very easy to machine.
What is the tensile strength of PU-Foam-Rigid?
PU-Foam-Rigid has a typical tensile strength of 6 MPa (0.87 ksi) — weaker than 90% of polyurethane grades. Strength varies by condition: see the 7 listed tempers.
Is PU-Foam-Rigid easy to machine?
Yes — machinability is rated excellent (88/100, better than 100% of polyurethane grades). Cuts and mills very easily with sharp single-flute or foam-specific tooling at high rpm/low feed; use vacuum extraction — the dust is fine and irritant — and expect cell tear-out on thin edges of low-density grades.
Can PU-Foam-Rigid be welded?
Thermoset and cellular: not weldable; join with PU/epoxy adhesives, dowels or embedded inserts potted in place.
What surface finishes work on PU-Foam-Rigid?
Skin sands well but the open core must be sealed with polyester filler or a 2K PU primer before painting; no plating, and UV exposure needs a pigmented/clear-coated topcoat to prevent yellowing.
Can PU-Foam-Rigid be formed, bent or molded?
Two-component pour under vacuum into silicone or epoxy tools at 25–40 °C mould temperature; meter accurately, degas, and control shot weight/vent layout since density and skin quality depend on constrained rise (demould typically 20–60 min).
What is the maximum service temperature of PU-Foam-Rigid?
PU-Foam-Rigid is rated for continuous use to about 85°C (185 °F), and briefly to 120°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
How much does PU-Foam-Rigid cost?
PU-Foam-Rigid is a premium-cost polyurethane ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- F-series rigid casting foams (technical data sheets) — Axson Technologies / Sika Advanced Resins (2022)
- FOAM-iT! rigid urethane foam series — Smooth-On (2023)
- ISO 844 — Rigid cellular plastics, compression test — ISO (2021)
- ASTM D1622 / D1623 — Apparent density and tensile properties of rigid cellular plastics — ASTM (2020)
- Polyurethanes Handbook (Oertel), rigid foam property–density relations — Hanser (1994)
- Cellular polymer property tables (rigid PU) — CAMPUS / Ashby CES material data (2023)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.