Transit bus OEM client required a soft-touch PU foam armrest with complex sculpted geometry, consistent shore hardness, and Class V flammability compliance (FMVSS 302) for mass transit procurement specifications.
Developed a self-skinning integral-skin PU foam compound with Shore A 45±3 hardness. Designed 2-cavity aluminum mold with consistent temperature control zones. Validated flammability to FMVSS 302 Class V.
Zero assembly rework. Passed FMVSS 302 Class V in first-article testing. Annual production volume of 80,000 units at 99.7% first-pass yield.
DFM Analysis: Mold parting line optimized to eliminate flash on visible surfaces. Draft angle analysis resolved 3 areas where skin tearing risk was identified.
Our engineers work from your CAD drawings before any tooling begins — identifying potential failure modes, proposing material alternatives, and validating gate/cooling layouts digitally. This eliminates costly mold revision cycles.
Physical test results from production samples — available with every shipment on request.
| Property | Specification | Tested Result |
|---|---|---|
| Shore Hardness | Shore A 45 ± 3 | Shore A 46 |
| Skin Density | ≥ 800 kg/m³ | 820 kg/m³ |
| Core Density | 80–100 kg/m³ | 88 kg/m³ |
| FMVSS 302 | Class V pass | PASS — 0 mm/min burn rate |
Share your drawings, quantity and material requirements. Our team performs a complimentary DFM review before quoting.
