Flexible polyurethane foam (FPF) is a polymer produced from the reaction of polyols and isocyanates, a chemical process pioneered in 1937. FPF is characterized by a cellular structure that allows for some degree of compression and resilience that provides a cushioning effect. Because of this property, it is a preferred material in furniture, bedding, automotive seating, athletic equipment, packaging, footwear, and carpet cushion. It also plays a valuable role in soundproofing and filtration.

Foam is most commonly produced in large buns called slabstock, which are allowed to cure into a stable solid material and then cut and shaped into smaller pieces in a variety of sizes and configurations. The slabstock production process is often compared to bread rising—liquid chemicals are poured onto a conveyor belt, and they immediately begin foaming and rise into a large bun (typically about four feet high) as they travel down the conveyor.

The basic raw materials for FPF are often complemented with additives that yield desired properties. These range from the comfort and support needed for upholstered seating to the shock-absorption used to protect packaged goods, to the long-term abrasion resistance demanded by carpet cushion.

Amine catalysts and surfactants can vary the size of cells produced during the reaction of polyols and isocyanates, and thereby vary foam properties. Additives can also include flame retardants for use in aircraft and automobiles and anti-microbials to inhibit mold in outdoor and marine applications.

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