PH: 800.806.6051 INTL: 253.473.5000

Polyurethane Smooth Finish Tooling Foam


Fine cell 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 microballoon-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.

Click here to request a sample of this product.

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.

Fine Cell Foam for 3-D Signage, Prototypes and Models

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 sign boards 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.

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

Tooling Applications

  • 3-D Signage
  • Design prototypes
  • Appearance or “sight” models
  • Architectural models
  • Topographical maps
  • Tooling and molds for low-temp. processes
  • Decorative moldings

 Sizing Chart


Products Density (lbs/ft3) Height (in) Width (in) Length (in)
FR-4615 15 14 60 120
FR-4615 15 24 48 96
FR-4618 18 12 60 120
FR-4618 18 24 48 96
FR-4625 25 18 48 96


Products Density (kg/m3) Height (cm) Width (cm) Length (cm)
FR-4615 7 60 120 240
FR-4615 7 35 150 300
FR-4618 8 60 120 240
FR-4618 8 35 150 300
FR-4625 11 45 120 240

Shown are maximum standard stock sizes based on density. Custom sizes are available. Cut sizes are available from .125 inches (3.175 mm) up to standard stock heights as listed above.