Rojac Urethane Ltd are one of the top PU Moulders in the UK serving a wide variety of market sectors.

Please feel free to contact us for any help and technical advice, whether your looking to develop new foam components or you are not sure on hardness and density, which inserts can be used, the best PU foam for your parts or prices and delivery on tools and PU mouldings, we are here to help.

Please email us or give us a call!


We can read most CAD formats including Catia, IGES, STEP, STL, DXF etc..

STEP format is always our preference.

Send us your CAD files directly


High Resilience Flexible Foams

Primarily used for seating applications in the automotive industry. All formulations are based on MDI chemistry, the resulting moulded foams comply with the requirements of JLR standard STJLR.51.5142. Dual Hardness foam components may be produced as required. Typical examples include front and rear cushion and seat backs, headrests and armrest.

Combustion Modified High Resilience Flexible Foams (CMHR)

Used for seating applications in high quality domestic and office furniture, in addition to public transport vehicle seating. All formulations based on M.D.I chemistry; the resulting foams comply with the flammability requirements of the ‘Crib 5’ test.

Semi Rigid Flexible Foams

A relatively firm flexible foam primarily used for interior trim applications in the automotive, transport and furniture industries. Typical examples include console pads etc. Components in a range of hardness’s and densities may be produced to suit the application.

Integral Skin Foams

Self-finished moulded foam primarily used for trim applications in transport, appliance, equipment and furnishings industries where a hard wearing and impervious sealed surface condition is required. Typical examples include armrests for office furniture, automotive head restraints, component handles.

Graphite foams

Primarily used for seating applications where a high flame redundancy is required for example, rail and aircraft seating, graphite filled foam can meet the flammability requirements of the ‘Crib 7’ test as a part of a composite with a fire blocker and covering materials.

Rigid Foams

A solid polyurethane foam used in a diversity of applications where light weight solids with good thermal insulation and impact energy absorption properties are required. These can be produced in a wide range of material densities. Typical examples include thermal insulation panels for freezers, pipeline insulation and support systems, automotive filler pads, buoyancy fillings and equipment cases etc.

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Hardness and density are two separate characteristics in foam.

Hardness is the load bearing (firmness) of the foam.

Density is the weight per unit volume measured in KgM3.

Both hardness and density can be varied independently in foam mouldings and we very often mould a range of parts with a variable selection of hardness and density for the customer to approve at the beginning of each project.

The hardness of different foam systems is measured and reported in different ways, flexible foams for example tend to measured and reported in kPa’s (kilopascals) whereas integral skin foams are measured using Shore A.

Flexible foams are measured using our Testometric M500CT Universal testing machines running Integral PC system running winTest™ Analysis universal testing software.

Integral skin foams are measured using a durometer, shore Hardness is a measure of the hardness of a given material or how resistant it will be to indentation. It is measured by the depth of indentation that is created on the material with a specified force.


We can mould in or over-mould inserts into most PU foam systems, this can include trim wires, wire frames, clips, Velcro, plastic components and frames, metal plates, plywood, fleece, Milliken etc..

PU foam has excellent bonding properties so is ideal for over-moulding inserts.


  • 2 or 3 shifts – up to 24 hours production per day
  • 30+ Production employees
  • Numerous high and low pressure foam machines
  • Production carousels with Kuka Robot 6 axis
  • Production turntables
  • Free standing prototype mould carriers
  • Capacity to increase workforce and turntables
  • Large factory area with room for growth and storage, large outside yard


Rojac specialise in full volume specialist PU foam moulding programmes.

We can mould any number of parts from a just few prototypes to thousands of foams, we mould in volume production for a number of prestigious clients with weekly deliveries working to demanding delivery schedules.

With several production moulding lines including 6 axis robotic pouring an automotive seat foam production carousel and several smaller part turntables Rojac support higher volume moulding of polyurethane parts for many prestigious clients.

  • 3 shifts - 24 hour production
  • High pressure foam machines 
  • Low pressure foam machines
  • Production carousel with Kuka Robot 6 axis
  • Production turntables
  • Free standing mould carriers
  • Moulded in inserts, wires, clips, Velcro, frames
  • Dual hardness moulded foams
  • Advanced product quality planning (APQP)


The ideal solution for prototype and development of polyurethane foam mouldings, Rojac have developed a cost effective rapid method of moulding PU foam parts that gives a real alternative to milled foam samples.

This process is often used in the place of milled foam parts for development and prototypes, the advantage against milled samples includes the fact that the rapid foam tool can produce multiple parts, can be easily modified and that mouldings can be produced to the correct hardness including moulded in inserts.

This process has been successfully utilised for many automotive 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.

  • From CAD to moulded PU foam mouldings in 7-10 day
  • Mould multiple foams from the same tool
  • Parts moulded to required hardness/density
  • Dual hardness parts if required
  • Production intent moulded foams
  • Inserts, wires, clips, velcro moulded into foam
  • Cost effective alternative to milled foam parts 
  • Tools can be easily modified (material on or off tool)
  • Production intent parts early in development stages of the project
  • Complete car sets moulded, including front seat cushion, squab, headrest, rear seat 40% and 60% squabs, full rear seat cushion, headrests, bolsters and inserts


Timing for your project will depend on the complexity of the parts, the data we work from the type of tooling we manufacture and the PU foam system required.

We can work from 3D CAD data supplied, design your parts for you from scratch or reverse engineer back to CAD data from samples making changes if required.

If we work from CAD data then typically;

Rapid prototype tooling and parts

7-10 days from CAD to moulded foams

Low volume or complex prototypes 

3-4 weeks from CAD to tooling and moulded foams

Production parts from aluminium tools

4-5 weeks from CAD to tooling moulded foams

These are only guidelines; contact us for a quotation and we will provide a more accurate delivery which is subject to capacity at the time of order.


All foam mould tooling is designed in house and manufactured utilising our approved UK local toolmakers, Rojac have developed a number of quality toolmakers over the years and work closely with them to ensure a reliable, competitive and quality service, tooling is manufactured directly from CAD data supplied or reverse engineered from samples, we also offer a complete design service designing both components and tooling.

Foam tooling is designed to suit the volumes required along with the PU foam materials being used.

A number of options are available for tooling to suit your budget and the volumes required.

Metal tooling for integral skin PU foams can also include texture / graining.

Tooling is designed to fit our PU foam moulding presses or to be hand clamped to fit various turntables.

Tooling type Typical Lead-times from CAD
Rapid Prototype Tooling* 7-10 working days
Aluminium Billet Tooling 4-5 weeks
GRP Resin Tooling 5-6 weeks
Cast Aluminium Tooling To be advised

*Rapid prototype tooling guaranteed for a maximum of 100 parts

Tool Modifications

Rapid tools can be modified material on or off.

Aluminium tools can be modified material on or off subject to extent of modifications required.


Tooling can be designed to carry inserts these can include trim wires, clips, wire frames, Velcro, fleeces, plywood, metal frames and plastics, inserts can be held in the tool by magnets, clips etc..


Monday to Thursday 6:00am to 10:00pm.

Friday 6:00am to 3:00pm.

Saturday and Sunday closed.

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