Custom-Cut Polyurethane Solutions for Foundry, Tooling & Prototyping
Foam That Holds Its Shape Through the Entire Build Process
In pattern making, dimensional accuracy is everything. Our rigid polyurethane foams are designed to resist warping, shrinkage, and distortion — even under mechanical or thermal stress. This makes them ideal for producing patterns used in sand casting, composites layup, and vacuum forming.
Their uniform cell structure allows for precision machining and easy finishing, ensuring smooth surfaces, sharp edges, and consistent replication from one mold or tool to the next.
Used in Foundries, Aerospace, Marine, Automotive and More
Our foam products are used by toolmakers and designers across a wide spectrum of industries. In the foundry sector, they enable precise pattern creation for casting aluminum, bronze, and iron. In marine and aerospace, they support tooling for complex composite structures. And in automotive, they’re used for rapid prototyping, jigs, and fixtures.
Southern Urethane offers foams in a variety of densities and formats to suit both large-scale fabrication and intricate detailing. No matter the industry, we help you achieve quality, repeatable tooling outcomes.
Common Use Cases
- Foundry pattern making and sand casting molds
- Composite tooling and master plugs
- Automotive prototyping and design validation
- Aerospace and marine structure molds
Seamless & Efficient
Custom Block Sizes and Expert Guidance for Any Project
Made to Your Specs
We understand that every pattern making project is different. That’s why we offer custom-cut foam blocks and billet sizes to fit your machine bed, tooling envelope, or fabrication workflow. Whether you need large-format blocks or fine-detail sections, we’ll tailor the foam to your requirements.
Why Choose Us
- Custom sizes and densities available
- Short lead times and reliable local supply
- Expert advice on foam selection and usage
- Supporting small shops to major manufacturers