Moulded foam for chairs that perform daily

Our moulded foam components form the sturdy yet comfortable core of office chairs, work chairs, stools, and saddle seats. They provide long-lasting comfort while retaining their shape, even under intensive daily use. Whether you opt for a standard solution or a custom model, our moulded foam products fit your application perfectly and meet your quality requirements.

Why choose PU moulded foam?
Polyurethane (PU) moulded foam is the trusted choice for seating solutions that see heavy daily use. Our high-quality PU foam seats and backrests offer benefits that truly make a difference:

• Flexible: adapts easily to complex shapes and designs
• Comfortable: resilient, ergonomic support
• Durable: resistant to wear, built to last
• Shape-retaining: maintains its original form, even with daily use
• Professional appearance: stays neat and visually appealing
• Efficient: suitable for scalable production while maintaining consistent quality

Thanks to these qualities, our moulded foam components are ideal for seating in healthcare, laboratory, industrial workspaces, and modern office environments.

Technology you can rely on
Moulded foam is created when two liquid polyurethane components are poured into a mould, where they react to form a solid, resilient foam shape. By adjusting the ratio of the components, the firmness of the foam can be precisely tailored to the intended application. The firmness is measured with a Shore-F meter and, for most models, ranges between 50° and 70° Shore F – solid, yet still comfortably supportive.

Most of our moulded foam components are reinforced with an inlay of wood, plastic, or metal, which is molded directly into the foam. These inlays can be equipped with threaded inserts, ensuring fast and reliable assembly in the final product. Plastic covers provide chair components with a clean, professional finish. Available as standard in sleek black.

Customisation is in our DNA
Every project comes with its own challenges. That’s why we don’t stop at standard shapes. We design customer-specific solutions that fit seamlessly into real-world applications. Our expertise in mold design and development keeps customization surprisingly cost-efficient, while guaranteeing consistent quality, low unit costs, and efficient production.

Case in point
A good example is the compact neck and headrest we recently developed for an office chair manufacturer. The client was looking for an ergonomic solution that would deliver reliable comfort to users and maintain the same quality in large-scale production. By working closely together, we translated this need into a moulded foam component that proved both technically robust and comfortable in everyday use.

For us, it was essential that the neck and headrest provide the same quality and support in every chair. Thanks to the moulded foam and the collaboration with ACP, we achieved exactly that result.

_{Co-created headrest with our client}

Ready to use: upholstered models
Need a quick start? Our moulded foam components are also available with a ready-to-use black faux leather upholstery. Easy to maintain, professional in appearance, and a perfect fit for common design styles. Ideal if you want to save time without compromising on looks.

Working together for comfort
Curious how our high-quality moulded foam components can strengthen your production line? Our specialists work with you to find the right solution and make sure you can move forward quickly. Get in touch with our sales team. Just Ask!