An Essential Guide to Polyurethane

21st July, 2025

Made from polymers and urethane combined during a chemical reaction, polyurethane is a unique material that can be manufactured in a variety of hardnesses, from the softness of a pencil rubber to something harder than nylon, and anywhere in between.

This essential guide to polyurethane will discuss the properties and benefits of polyurethane, its uses and industry and how open-cast moulding and sheeting can be manufactured for a range of custom projects.

Properties and benefits of polyurethane

Often, people wonder if polyurethane is rubber or plastic because it sometimes looks and feels like either one of the materials. However, polyurethane is a unique polymer that is elastic like rubber, but can be repeatedly stretched and reformed like plastic can be. Also, polyurethane has the toughness of metal.

Because of this, polyurethane has several benefits.

Longevity

Depending on where it is used, polyurethane has an extremely long lifespan under normal wear and tear conditions. For example, a lifespan of more than 50 years is expected for polyurethane insulation systems in building, more than 25 years for polyurethane found in refrigerator insulation and over 20 years for polyurethane in vehicle bumpers.

Abrasion resistance

Polyurethane is highly resistant to abrasion, meaning it can withstand significant amounts of friction and impact. If an application is prone to severe wear, like conveyor belts, wheels and components in mining, quarrying or industrial machinery, polyurethane is an ideal solution to extend the lifespan of an application. It even remains resistant to abrasion at low temperatures.

Oil and chemical resistance

Polyurethane has strong oil and chemical resistance levels, meaning they are a versatile material choice for various applications across multiple industries. Most polyurethanes are resistant to pure mineral oils and fats, as well as many chemicals, including weak acids and bases, solvents and water. This means they are an ideal choice for use for industrial seals and gaskets, like those used in the offshore and wind industry. Polyurethane can also protect industrial applications in the oil and gas industry because of its oil and chemical resistance.

Heat resistance

Regardless of whether your polyurethane is operating in extreme heat up to 120°C or in colder temperature below zero, it will remain functional to a high standard. Specialised heat-resistant polyurethane can be selected for applications facing extreme heat, but if your application does not need to run in a high temperature environment, you can opt for general polyurethane instead.

Polyurethane has additional benefits too, including its ability to repel water after the correct number of coatings, its affordable manufacturing process and its antistatic nature.

Polyurethane in industry

The varied properties of polyurethane means it can be used across several industries in different applications, from everyday applications to industrial and specialised uses.

In the home, polyurethane is a crucial factor in applications we use on a daily basis. Kitchen and bathroom sponges are often made from polyurethane because it is tough and durable but flexible and absorbent. Your watch strap may be made from polyurethane to ensure comfort for the wearer, or your footwear probably contains polyurethane materials because it keeps its integrity under duress and provides better foot support. Polyurethane is commonly used for comfort in the home, in mattresses, desk chairs and building insulation.

Polyurethane is also commonly used in industrial applications, like automotive. Your car is likely to have polyurethane materials in the armrest, headrest and seat. If you have a holiday home and travel the country in a caravan, bespoke caravan seals made from polyurethane can seal window frames or doors, whilst car tyres are made from polyurethane because of its strong grip and flexibility.

Medical and scientific equipment, like general-purpose tubing, surgical drapes and wound dressings because of its flexibility, abrasion and tear resistance, and strength. Polyurethane coatings can be used in cars and construction to provide a protective varnish to defend against dents and scratches from the weather.

Polyurethane open-cast moulding & polyurethane sheeting

Open-cast urethane and polyurethane moulding can be used to provide a wide variety of products because they surpass other polymers for applications requiring the following:

• High abrasion resistance
• Outstanding tensile and tear strength
• Noise dampening
• Chemical resistance
• Excellent load-bearing capability.

Urethane can replace metal casting. It is lightweight but still maintains or exceeds wear characteristics found in their metal counterparts. Also, the ingredients in some urethanes are FDA approved, so can be used to make contact with foodstuffs.

Polyurethane sheeting can be produced in several dimensions through methods including centrifuged, flat, cast, moulded and extruded. They can be applied to cutting or punching gaskets, scrapers and flaps, protecting industrial tabletops, lining wear chutes and blast cabinets.

Aquaseal Rubber’s bespoke polyurethane products

Since all rubber and polyurethane products deteriorate at some point in their lifespan, it is crucial to inspect and check your applications before use. At Aquaseal, we have provided polyurethane products to clients on several occasions, including polyurethane mouldings and polyurethane roller covering.

If you are looking for new or replacement bespoke polyurethane products for your project or applications, contact us to discuss your specific requirements and needs.