Polyurethane Foam Moulders
Innovative solutions for technically challenging PU foam problems

Rojac Urethane Ltd specialise in polyurethane foam moulded components, we are a UK West Midlands based PU foam moulder supplying both OEM's and Tier 1 suppliers.

Moulding PU foams for a wide variety of market sectors including Automotive, Rail and Aircraft seating, headrests and armrests.

Specialist moulders of PU flexible foam, integral skin and rigid foam.

The complete end-to-end solution

UK based PU Foam moulders from development through to prototype and full volume production foam moulding.

specialist polyurethane development



product development prototyping



high volumne production



Specialist Polyurethane Development

With a wealth of experience in PU foam technologies Rojac have the capability and knowledge to develop, prototype and production mould your polyurethane projects.

Working from CAD data, samples, drawings or even just sketches we will advise on tooling and PU foam systems to suit your requirements.

Collaborating with our or polyurethane raw material suppliers we can advise materials based on your parts requirements, we also develop new and variations of existing PU systems pushing the boundaries on hardness, dual hardness, densities, flame redundancy, durability, inserts and more.

With an in-depth knowledge in PU foam moulding Rojac offer a first class service in tooling design, manufacture and PU foam moulding to a wide variety of industries and a broad range of applications.

Product Development Prototyping

Prototype milled seat foams CNC machined to CAD data for one off quick prototypes.
Foam mouldings typically in 7-10 days from CAD to moulded PU part, comfort and trim trials, quick and cost-effective modifications to tooling to allow fast product development.

  • Production reprehensive parts in days
  • Dual hardness
  • Moulded in inserts, wires, clips, velcro
  • Multiple parts with a range of hardness and density

High Volume Production

Full volume production foam moulding utilising robotic 6 axis pouring and production carousels, mould turntables and aluminium production PU foam tooling.

Production mould tools designed and UK manufactured in short lead-times.

Specialists in full volume specialist programmes and technically challenging parts.

Covering a multitude of sectors

Our extensive polyurethane foam moulding facilities include moulding dual hardness HR flexible PU foam, crib 7 graphite foam, crib 5 melamine CMHR foam, Integral skin foam and rigid foams for a wide variety of market sectors including:



Rapid tooling for Rapid PU prototyping

From CAD to moulded foams in 7-10 days

As one of the top PU Moulders in the UK serving a wide variety of market sectors, moulding a diverse range of bespoke products utilising the very latest in polyurethane moulding technologies.

From one off prototypes through to development of foams for comfort, trim development and prototype builds onto full production of moulded foam parts.

Prototype through to full production moulding.
Prototype moulded foams to production quality in days not weeks.
Specialists in Automotive seat foam moulding.


Ideal for Automotive seat foam development.

Dual hardness, moulded in inserts including trim wires, Velcro, wire frames and clips.

Production intent foams for trim development, comfort trials and H point adjustment, DV builds, including variable hardness and density.

This process has been successfully used for many vehicle seating projects allowing our customers to rapidly develop seat designs, foam hardness and comfort trials in a fraction of the time traditionally taken to develop seating for new vehicles.

Production intent parts moulded in days not weeks!

Design changes? No problem rapid tooling can be easily modified material on or off.

1. Rapid Quote - Send us your CAD and we will quickly provide you with a competitive quotation for our rapid tooling and moulding services.

2. Rapid Tooling - Rapid tooling designed and manufactured in days not weeks.

3. Rapid Moulding

  • Hardness and density varied as required
  • Dual hardness
  • Moulded in inserts.
  • Used in the development of many new automotive projects

4. Rapid Testing - Parts hardness tested and full graphical reports supplied.

Whole process typically just 7 - 10 days from CAD to moulded foams.

Working with some of the best manufacturers on the planet...

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