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Tjikko product
Molded Foam
Custom-Shaped Polyurethane Foam Custom-shaped flexible polyurethane foam produced by pouring isocyanate and polyurethane chemicals into client-specified molds.
Key specifications
Product overview
Built to your mold. Not the other way around.
Custom-shaped flexible polyurethane foam produced by pouring isocyanate and polyurethane chemicals into client-specified molds. The foam takes the exact shape of the mold and cures to a defined density and hardness. Tjikko's core product — fully custom, flexible MOQ, no fixed minimums. Sample orders welcome.
Technical data
Technical specifications
| Property | Value | Notes |
|---|---|---|
| Material | Flexible Polyurethane (PU) | Isocyanate + Polyol blend; custom formulations available |
| Density Grade Range | D10 – D90 | Standard: D10, D18, D23, D32, D40, D45, D50, D65, D80, D90 |
| ILD Hardness | R40 – R90 | Custom ILD available on request |
| Compression Set | < 15% % | 70% compression, 22 hours (ISO 1856) |
| Resilience | 40 – 65 % | Varies by density grade |
| Tensile Strength | > 80 kPa | Suitable for flexible foam applications |
| Tear Resistance | > 200 N/m | Durable for high-wear seating |
| Temperature Range | -20 to +80 °C | Operational range for industrial applications |
| Cell Structure | Open-cell | Flexible and breathable |
| Lead Time | 7–14 working days | After mold confirmation and order placement |
| MOQ | Flexible | No fixed minimum — sample orders welcome |
| Certification | FMVSS 302 | Available on request; in-house lab testing |
Density visualisation
Applications & use cases
Where this foam is used
This product is used across multiple B2B industries in Indonesia and export markets.
View all industriesCar seat cushion
Automotive · 35–50 kg/m³
Motorcycle seat
Automotive · 40–55 kg/m³
Sofa / couch cushion
Furniture · 28–40 kg/m³
Office chair seat
Furniture / Office · 35–45 kg/m³
Gaming chair foam
Consumer Electronics · 40–55 kg/m³
Auditorium chair
Hospitality / Public · 35–50 kg/m³
Cinema seat
Entertainment · 35–50 kg/m³
Medical device cushioning
Medical / Health · 40–65 kg/m³
Sports padding / guards
Sports Equipment · 25–45 kg/m³
Manufacturing process
How it's made
Based on industrial polyurethane continuous production system
Formulation
MMDI system calibrated for target density and reactivity.
Cannon injection
Mixed chemicals injected into client-specified PU mold cavity.
Curing in mold
Foam cures to exact shape at controlled time and temperature.
Demold & trim
Foam released from mold; flash and skin trimmed to specification.
Lab QC
Density, ILD hardness, and compression set tested per batch.
OEM docs & delivery
Invoice, packing list, Certificate of Origin. Nationwide + export.
Common questions
Common questions
Technical and commercial questions answered directly.
What density grades are available for custom molded foam?+
Tjikko offers molded foam in density grades from D10 to D90 kg/m³. Standard available grades are D10, D18, D23, D32, D40, D45, D50, D65, D80, and D90. ILD hardness ranges from R40 to R90. Custom density formulations are available for specialized applications — contact our sales team with your engineering specification.
What is the minimum order quantity for molded foam?+
There is no fixed minimum order quantity for molded foam. Tjikko accommodates sample orders for testing and approval, as well as large recurring production orders. MOQ depends on the complexity of the mold and the order. Contact our sales team with your specification for a tailored quote.
How long does production take for custom molded foam?+
Standard production lead time for custom molded foam is 7 to 14 working days after mold confirmation and order placement. Fast-track production may be available for standard configurations. Complex molds or specialty formulations may require additional time. We will confirm lead time when reviewing your specification.
Can Tjikko manufacture foam to an existing mold drawing or CAD file?+
Yes. Clients can provide a mold drawing, CAD file, or a physical sample. Tjikko will assess the feasibility and manufacture the mold to your specification. There is no fixed size limit for custom molds — feasibility is confirmed upon inquiry. This is the standard OEM workflow for furniture and automotive clients.
Is FMVSS 302 certification available for automotive molded foam?+
Yes. Tjikko has an in-house chemical testing laboratory and can provide FMVSS 302 (Federal Motor Vehicle Safety Standard — flammability) certification for molded foam used in automotive seating applications. Other certifications are available on request. Contact us to discuss your compliance requirements.
What is the production capacity for molded foam?+
Tjikko's molding line can produce approximately 3,360 pieces per shift with one machine (net ~3,192 after quality loss). With two machines operating across two shifts, capacity increases to approximately 6,283 net pieces per day, or ~125,660 pieces per month. Capacity scales for recurring orders.