Comparative Analysis of the Use of Polymers and Release Agents in Mold Manufacturing for Polyurethane Foam (PUR) Production

Abstract

This study focuses on optimizing the demolding process in polyurethane foam (PUR) production evaluating the interactionbetween different polymeric materials used for mold manufacturing and release agents. Three polymers—polyamide (PA), poly-acetal (POM), and polypropylene (PP)—were tested with water-based and solvent-based release agents assessing their effective-ness in reducing PUR foam adherence. Specimens were fabricated by CNC machining and surface roughness, hydrophobicity,demolding energy, and peel-off stress over four cumulative foam manufacturing cycles have been measured. PP, particularlycombined with water-based release agents, exhibited significantly lower PUR foam adherence (2–7 times less), surface roughness(3–18 times less), and required demolding energy (1–12 times less) than PA and POM. Statistical analysis confirmed the moldmaterial as the most influencing factor in the process. These findings suggest that PP offers the most efficient demolding process,reducing both energy consumption and surface wear, providing a new way to improve efficiency and sustainability in PUR foamproduction. In conclusion, low adhesion polymeric materials can be an alternative to the metallic materials commonly used inthe manufacture of molds for the PUR foam manufacturing process, leading to significant improvements in sustainability andefficiency