What is foam casting?
Foam casting pours a two-part polyurethane foam system into a mold, where the components react and the mixture rises (expands) as it cures into a rigid or flexible foam part. Because the foam is expanding while it sets, the A:B ratio and the speed of mixing and pouring directly drive the final density and surface.
- Rigid and flexible PU foam parts
- Lightweight cores, fillers, and packaging-style inserts
- Props, models, and low-volume foam components
Why manual foam casting is hard
- Fast reaction: Foam systems often have a short cream/rise time — hand-weighing wastes that window.
- Density variation: Off-ratio batches rise too much or too little, giving inconsistent parts.
- Voids and short fills: Uneven mixing leaves un-reacted pockets.
How Flovv helps
Flovv meters both components at a fixed ratio and blends them through a static mixing nozzle, so the foam starts reacting from a consistent, even mix every time. Process notes: prep and release your mold, account for expansion when you set the shot volume, and respect the system's cream and rise times. For two-part PU foam specifically, this is the same foam-capable workflow behind Flovv-e.
Pick the right system for your run: see the Flovv injection system, the foam-capable Flovv-e, or browse all products.