Gap Filling & Sealing

PU Foam — Micro-Cellular Polyurethane Pads

Soft, compressible micro-cellular polyurethane foam engineered for gasket sealing, cushioning, vibration damping and gap filling — in electronics, battery packs, and enclosed assemblies.

Request a Quote WhatsApp Us Back to Products

High compress & recovery Flame-retardant options Die-cut to shape

Soft & sealingCushions & conforms

What it is

Micro-cellular foam that compresses, seals and recovers.

Micro-cellular polyurethane (PU) foam is a soft, evenly celled material that compresses under load and recovers its shape when the load is released. Its fine cell structure lets it conform to uneven surfaces, filling gaps and forming a reliable seal or cushion between mating parts.

Supplied as sheets and custom die-cut pads, it is widely used where parts need protection from shock, vibration, dust or moisture ingress inside compact enclosures.

Why engineers choose it

Conforms, cushions and seals in tight spaces.

Excellent compressibility and shape recovery
Conforms to uneven surfaces for effective sealing
Absorbs shock and damps vibration
Fills gaps and tolerances between mating parts
Flame-retardant options available

What It Does

Four jobs, one material

Micro-cellular PU foam earns its place across sealing, cushioning, damping and gap-filling duties.

Gasket sealing

Conforms to mating surfaces to form dust and moisture seals around enclosure lids, doors and access panels.

Cushioning

Soft, recoverable padding that protects delicate components and cells from shock and impact inside assemblies.

Vibration damping

Compressible foam that isolates and dampens vibration and micro-motion between parts in moving or noisy environments.

Gap filling

Fills uneven gaps and tolerances between components, taking up stack-up variation and preventing rattle or movement inside packed enclosures.

Typical Applications

Where PU foam is used

Wherever a soft, sealing, cushioning interface is needed inside an assembly.

Battery & BMS packs

Electronics enclosures

LED drivers & SMPS

EV charger housings

Gaskets & lid seals

Shock & rattle padding

Formats & Supply

Configured to your dimensions

Sheets and die-cut pads to your size, thickness and quantity. Tell us what you need and we’ll confirm the right grade and quote.

Custom die-cut shapes

Die-cut pads and gaskets converted to your drawing, with consistent dimensions across repeat production runs.

Sheets & thicknesses

Sheet supply in your required thickness and size, with density and grade confirmed against your application.

Flame-retardant options

Flame-retardant grades available where enclosure or battery-pack requirements call for them — confirm on request.

Exact density, hardness and thickness ranges depend on the selected grade and application. Share your requirements and we’ll confirm the right material and send the matching datasheet.

Ready to specify your PU foam pads or sheets?

Share the thickness, density, size, shape and quantity — or send your drawing. We’ll confirm the right grade and quote it.

Request a Quote Back to Products

Request a Quote

Tell us your PU foam requirement

Thickness, density, size, shape and quantity — or attach your drawing. We’ll confirm the right grade and pricing.

Micro-cellular PU foam: terms and supply

Micro-cellular polyurethane (PU, also written PUR) foam is a soft, fine-celled foam that compresses under load and recovers when the load is released. Perfect Insulations supplies it as sheets and as die-cut pads and gaskets cut to the customer's drawing in Bengaluru, with flame-retardant grades on request. It is one of the materials in our die-cut insulation parts service.

Key terms

Term	Meaning
PU / PUR	Polyurethane. PUR is the standard abbreviation for polyurethane in ISO 1043; micro-cellular polyurethane is often written MCPU.
Micro-cellular	A foam with very small, evenly sized cells. The fine structure gives a smooth surface and consistent compression across the sheet.
Compression pad	A die-cut foam pad fitted under slight compression between two parts — for example between cells in a battery module — so it keeps an even contact force as the parts expand, contract or vibrate.
Compression set	The permanent deformation left after a foam has been held compressed for a set time and temperature, as a percentage of the compression applied. A lower value means better recovery.
Compression force deflection (CFD)	The force needed to compress a foam sample by a set percentage of its thickness; a measure of firmness.
Density	Mass per unit volume of the foam, in kg/m³.
Flame-retardant grade	A foam formulated to meet a flammability rating, such as the UL 94 foamed-material classes HBF, HF-2 and HF-1.

Frequently asked

What is micro-cellular PU foam?

Micro-cellular polyurethane (PU or PUR) foam is a soft, evenly celled foam that compresses under load and recovers its shape when the load is released, so it can seal, cushion, damp vibration and fill gaps between mating parts.

In what formats does Perfect Insulations supply PU foam?

As sheets in the required thickness and size, and as pads and gaskets die-cut to the customer's drawing at our Bengaluru works, with consistent dimensions across repeat production runs.

Are flame-retardant PU foam grades available?

Yes. Flame-retardant grades are supplied where an enclosure or battery-pack requirement calls for one; state the requirement with the enquiry.

What details are needed to quote PU foam pads?

The thickness, density, size, shape and quantity, or a drawing. The datasheet for the quoted grade is sent with the quotation.

Where is PU foam used?

In battery and BMS packs, electronics enclosures, LED drivers and SMPS, EV charger housings, gaskets and lid seals, and as shock and rattle padding.

Do you ship PU foam parts across India?

Yes. Parts are dispatched from Bengaluru by courier, or surface freight for bulk consignments. Prices exclude 18% GST; Karnataka orders are billed CGST+SGST and other states IGST.

Full product catalogue

Browse every thermal and electrical insulation grade we manufacture, with full specifications.

Silicone thermal pads Gap filler pads FRP / epoxy glass sheet

Browse all products →