Microcellular Polyurethane Foam - Smooth Finish Tooling Foam | General Plastics
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Polyurethane Smooth Finish Tooling Foam


Microcellular polyurethane foam supports the most intricate detail while eliminating extra prep work. With an even-smoother surface finish than our FR-4500 tooling material, it is superb for precision tooling applications, or as modeling foam. Advanced microcell technology creates a grain-free, ultra smooth exterior for painted finishes, significantly reducing process time. What’s more, its finer cell structure is comparable to higher-density products without the added cost and weight.

Unlike more dense glass micro balloon-filled syntactic foams, this material greatly reduces tooling wear. The high-density polyurethane foam is easily worked using CAD/CAM routers and CNC machines – or the simplest woodworking tools. The FR-4600’s exceptional machining characteristics also make it an efficient material to create intricately patterned masters for composite and layup tools and for mold and foundry patterns.

Smooth Finish Foam for Tooling & Molds

FR-4600 Microcell Board, designed for tooling use up to 200°F, is well-suited for layup tools with low-temperature curing prepregs, and other low-temperature processes. This superfine tooling material produces remarkably crisp edges with exceptional dimensional stability.

Microcell Foam for 3-D Signage, Prototypes, and Modeling

Our FR-4615 & FR-4618 are excellent edge definition paired with the microcell ultra smooth surface, makes our FR-4600 material an outstanding alternative to wood in outdoor signboards and display manufacturing. With its superior cell structure, this board accommodates very fine surface finishes using virtually any coating system. Please visit our distributor SignArts for more information or samples.


FR-4600 tooling board machines exceptionally well. It is recommended that you do a rough cut first, leaving 1-3 mm of material for finishing.  Use caution at edges and tight corners to avoid chipping at the start of a new pathway and when exiting the foam.  See our Tooling & Molds User Guide for more information like roughing speed, finishing speed, and other machining information.

Advantages of Microcellular PU Foam

  • Ultra smooth finish
  • Lighter, less abrasive than syntactic boards
  • Creates intricate, 3-D details
  • Faster sealing and finishing
  • Dimensionally stable
  • Special formulation allows creation of shavings when material is machined
  • Easily finished with nearly any resin or coating system
  • Reduced cutting tool abrasion
  • Large sheets up to 60″ x 120″
  • Easily bonded for large block sizes
  • Max use temperature of 200°F (93°C)
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Tooling Applications


ProductsDensity (lbs/ft3)Height (in)Width (in)Length (in)Request a Quote
FR-461010244896Quote »
FR-4615151460120Quote »
FR-461515246096Quote »
FR-4615151448120Quote »
FR-461515244896Quote »
FR-4618181260120Quote »
FR-4618181248120Quote »
FR-461818244896Quote »
FR-4625251260120Quote »
FR-462525184896Quote »
ProductsDensity (kg/m3)Height (cm)Width (cm)Length (cm)Request a Quote
FR-461516064122244Quote »
FR-461524036152305Quote »
FR-461828861122244Quote »
FR-461828861122244Quote »
FR-462540030152305Quote »

Shown are maximum standard stock based on density. Custom sizes are available. Cut sizes are available from 0.125 inches (3.175mm) up to standard stock heights as listed above

Related Resources

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Technical Papers

Machining vs Cast Molding: Choosing the Best Manufacturing Method to Process Polyurethane Foam

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General Plastics to Introduce FR-4600 Microcell Foam Series at Aircraft Interiors Expo Americas, October 14-16, 2014

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