Microcellular urethane foam is the go to material when you need a thin, consistent gasket or cushion that compresses easily yet recovers every time. It is ideal for sealing, cushioning and vibration control in electronics, lighting, transport, appliances and more. At iTapeStore you can order standard sheets and rolls or have us laminate adhesive and convert the foam into ready to use parts for your production line.
Why Choose Microcellular Urethane Foam
Microcellular urethane foam is engineered for controlled compression. Its very fine cell structure provides a soft feel with excellent compression set resistance. That means it continues to seal and cushion after thousands of compression cycles.
Compared with conventional PU foam or rubber sponge, microcellular urethane typically offers.
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Very stable thickness control and tight tolerances for precise gasket designs
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Excellent compression force deflection control across the sheet so your seal behaves predictably
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Good vibration damping and impact absorption for electronics, handheld devices and equipment panels
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Long term durability in demanding assemblies including automotive interiors, appliances and industrial enclosures
It is widely used as.
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Dust and light seals in electronic housings and LED luminaires
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Gap filling and rattle prevention between plastic and metal components
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Cushioning pads under PCBs, batteries and displays
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Foam pads and bumpers where controlled compression is more important than high tensile strength
When combined with the right pressure sensitive adhesive, microcellular urethane becomes a high performance, peel and stick seal that can replace messy liquid sealants and mechanical fasteners in many assemblies.
Technical Specifications
Specific values will vary by grade. In general, microcellular urethane foams offer.
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Thickness range. Commonly from very thin 0.5 mm foams up to around 12 mm. with tight thickness tolerances for precision gasketing
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Density and firmness options. Multiple densities and compression force deflection options to match your required closure force and seal level
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Temperature performance. Many grades are suitable from approximately -40 °C up to 80–90 °C, with some high temperature versions available
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Environmental resistance. Good ageing characteristics in indoor and many sheltered outdoor applications, with options that offer improved UV resistance and solvent resistance when required
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Compression set resistance. Designed to recover after repeated compression, unlike cheaper foams that take a permanent set and lose sealing performance
When we add adhesive to the foam, we can match the adhesive system to your substrate and environment.
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Acrylic adhesives. Excellent long term holding power, good shear strength and tensile strength, better for high surface energy (HSE) metals and many plastics, and for applications exposed to higher temperatures, UV and chemicals
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Rubber adhesives. Very high initial tack, often preferred for difficult, low surface energy (LSE) substrates in indoor applications, especially when fast handling strength matters
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Specialty systems. Differential adhesives, removable one side and permanent the other, or adhesives designed to bond to powder coated metals and textured plastics
Our team can help you match foam grade and adhesive to your substrates, surface energy, temperature range and environmental conditions.
Custom Converting Options
iTapeStore is more than a tape and foam distributor. We are a Made in the USA converter specialising in short runs and production quantities.
We can supply microcellular urethane foam in.
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Master rolls or slit to your required width
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Sheets cut to standard or custom sizes
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Kiss cut parts on a roll for fast peel and stick application on the line
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Individual die cut gaskets, pads and spacers packed in bags or stacks
Need adhesive. We can laminate genuine 3M pressure sensitive adhesives to one or both sides of the foam and then convert to your finished part.
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Die cutting to complex shapes with internal cut outs and tight tolerances
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Laminating with liners suitable for manual application or automated dispensing
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Prototypes and test runs with no minimum order quantity on many configurations so you can buy by the yard and prove out your design before scaling up
Email sales@iTapeStore.com with your part number, substrate, dimensions and quantity. Our team will help specify a combination of foam and adhesive that meets your performance and cost targets.
Application Guide
Correct application is critical to achieve full bond strength and long term sealing performance.
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Surface preparation
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Ensure surfaces are clean, dry and free of oil, dust and release agents
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Wipe with a suitable cleaner such as isopropyl alcohol and allow to flash off completely
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For very low surface energy plastics or difficult powder coats, a suitable adhesion promoter or primer may be recommended
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Layout and positioning
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Dry fit your die cut parts to verify alignment and compression before removing the liner
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Avoid stretching the foam during application, as this can create internal stress and affect long term performance
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Application pressure
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Remove the liner and apply the foam to the substrate, starting at one edge and working across to avoid trapping air
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Apply firm, even pressure to activate the pressure sensitive adhesive and maximise contact with the substrate
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Cure time
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Many acrylic adhesives reach handling strength quickly, yet full bond strength typically builds over 24–72 hours, especially at lower temperatures
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Wherever possible, avoid putting the joint under maximum load until the adhesive has reached its recommended cure time
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Following these steps will help you get the best balance of shear strength, peel performance and long term sealing from your microcellular urethane foam.
FAQs
Is microcellular urethane foam removable
Removability depends on the adhesive you choose. Foam supplied without adhesive can be mechanically removed. When a high performance acrylic adhesive is used, the bond is usually permanent and may require mechanical removal or adhesive remover. If you need a removable or repositionable solution, talk to us about lower tack or differential adhesive systems.
Will this foam stick to powder coated or painted metal
Yes, with the right adhesive system. Many powder coats and paints are lower surface energy compared with bare metal. We typically recommend a high performance acrylic adhesive that is designed for these substrates and sometimes the use of a primer. Provide details of your coating system and we can recommend a suitable foam plus adhesive combination.
Can microcellular urethane foam be used outdoors
Some grades can be used in protected outdoor environments, especially when paired with an adhesive that offers good UV resistance and solvent resistance. For continuous direct UV and weather exposure, service life will depend on the specific formulation and design. Please share your application details so we can recommend an appropriate grade or alternative material.
What thickness and hardness should I choose
The right thickness and firmness depend on your gap, required seal level and available closure force. Thicker and softer foams will compress easily to take up larger tolerances, while firmer foams can provide a more robust seal under higher loads. Our team can help you select a grade that achieves the compression you need without overstressing your hardware or components.