Frequently Asked Questions

Microcellular polyurethane foam is a urethane foam with very small cell structure. ASTM terminology defines microcellular urethane as having cell diameters in the range of 0.0001 to 0.001 mm and a minimum density of 10 pcf.

A manufacturer-direct foam supplier can provide closer technical collaboration, faster material development, greater control over product customization, and direct support during testing and qualification.

HyPURcel® shares several important attributes with PORON®, including a microcellular polyurethane structure and the ability to be engineered across a range of performance requirements. Because application needs vary, material selection should be based on the specific performance criteria, thickness, density, and testing requirements for the end use.

hyPURcel® and PORON® are both microcellular polyurethane materials designed for engineered performance applications. hyPURcel® can be evaluated as an alternative where the required thickness, density, compression behavior, and application-specific properties align with the existing specification.

hyPURcel® engineers qualify an alternative foam supplier by reviewing the material specification, comparing key physical properties, testing prototype samples in the intended application, and validating long-term performance.

Yes. Rubberlite can compare existing materials against customer specifications and develop a hyPURcel® product to meet those defined performance requirements.

Compression set is permanent deformation or thickness loss that occurs when a foam or rubber material remains compressed for an extended period of time. Excessive compression set can reduce the long-term effectiveness of gaskets, seals, and cushioning products.

Yes. hyPURcel® I, R, S, T, and V Series products can be skived to the required application thickness, while F Series products are cast directly to the specified thickness.

Available thicknesses generally range from 0.040 in. up to 3.0 in., depending on the product series, target properties, and application requirements. Rubberlite can target specific thicknesses with custom tolerances.

hyPURcel® can be engineered to meet customer-specific performance requirements. Depending on the product series and application, available densities generally range from 5 to 32 pcf.

Using predictive compositional models and benchtop sample validation, new hyPURcel® foam grades can often be introduced quickly, sometimes in as little as a few weeks.

Rubberlite maintains ISO 9001 certification, and its characterization laboratory is accredited to ISO/IEC 17025.

Yes. hyPURcel® products can be developed to meet the requirements of existing designs that currently use PORON®, subject to review of the application requirements and validation testing.

Yes. hyPURcel® can be die-cut, and many converters currently process it for a wide range of applications.

Cushioning requirements vary by application. Some designs require firm material, while others require a softer product. In general, cushioning applications benefit from materials with low resilience, or low-ball rebound, because they help absorb impact energy.

When products require stability under heat, cycle rates and compression duration, hyPURcel® I-Series excels. It was specifically developed for demanding, repeat-use environments where dimensional stability and durability are critical.

Gasketing and sealing requirements vary by application. Some designs are dynamic, while others are static; some require only a dust seal, while others require an air or water seal. Products with strong compression set and compression fatigue performance are well suited for dynamic gasket applications. Open-cell microcellular foam may be appropriate for dust seals, while air and water sealing typically require an integral skin surface or a fully closed-cell structure.

Foams with a high degree of ball rebound, or resilience, are commonly used in athletic insoles because high energy return is often desired in these applications. Engineered for energy return under repeated compression, hyPURcel® R-Series is ideal for athletic insoles.

The best foam for vibration damping depends on the load, frequency range, available thickness, and operating environment. In general, materials with controlled compression behavior and strong energy absorption characteristics should be evaluated through application-specific testing to confirm performance.

hyPURcel® V-Series is a polyether-based polyurethane foam known for energy dissipation and pressure distribution through hysteresis loss and near-zero rebound. Unlike high-resilience or elastic foams designed for fast recovery, V-Series limits peak forces and vibration, making it ideal for applications that prioritize energy absorption. 

hyPURcel® foam is used in a variety of industries and applications, including footwear, orthotics, orthopedic soft goods, automotive, aerospace, medical cushioning, medical devices, die ejection, flexographic printing and much more.