Published by the Polyurethane Foam Association

www.pfa.org

Volume 1 | No. 2 (Revised 2016)

The Importance of Density

D
ensity is a key flexible polyurethane If the foam contains no 1 ft.
foam specification. It is an important additives or fillers, the
Flexible
indicator of foam performance with polymer density
polyurethane foam
regard to comfort, support and density is measured is the same as
1 ft.
durability. It is also an indicator of the relative in pounds per cubic foot the overall foam 1 ft.
economics of the foam. (pcf), or in metric terms, density. When
kilograms per cubic
The Definition of Density meter (kg/m3).
additives or
fillers are used in
Foam density is not weight. It’s actually a
measurement of mass per unit volume. Density is producing the foam,

a function of the chemistry used to produce the foam the foam density will be

including any additives or fillers that may used to impart specific higher than the polymer density.
Weight
performance features or to increase foam density. Flexible Generally speaking, the higher Density =
Length x width = height
polyurethane foam is available in a broad range of densities, the polymer density of the foam,
ranging from as low as 0.5 pcf to as high as 6 pcf. Polymer the greater the cost of the foam. Higher density foams
density is a function of the density of the virgin, or unfilled foam typically offer better physical properties including support
without factoring in possible additive content. and durability than lower
density formulations. It is
Typical Density Ranges for Different Foam Applications (pcf)
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 8.0 always important to determine
Packaging
whether the foam contains
Furniture Cushion Wrap
Furniture Seat Cushions additives or fillers, so that
Automotive Seat Backs a clear understanding can
Automotive Seat Cushions
be established as to the
Mattress Cores
Mattress Topper Pads & Upholstery polymer density compared
Carpet Underlay (bonded) to the foam density.

IN•TOUCH is a publication of the Polyurethane Foam Association (PFA) that covers topics of interest to users of flexible polyurethane foam.
How Density Affects Foam Performance height (e.g., a 4” thick sample to 3”) and then measuring the
The denser the foam, the more material used to produce it, deeper firmness (65% IFD) when compressing the same 4”
and the more material there is in the cushion to provide thick foam sample to 65 percent indentation. The ratio of the
weight support. 65 % IFD divided by the 25% IFD is the foam’s support factor.

It is important to remember, though, that foam surface firmness The higher the support factor, the greater the ability of the
is independent of foam density. High density foams can be foam to support weight. Foams with support factors of 2.0
produced to be very soft. Low density foams can be made to be or above are better suited for load bearing applications, like
very firm. Therefore, there is no such thing as “hard” or “firm” furniture seat cushions.
density. High density foam products generally offer great deal of
Density also can affect foam durability. Again, the more
support, but they can be manufactured to be fairly soft foams.
polymer material used to produce the foam, the better foam
What’s the difference between firmness and support? Firmness, tends to retain its original properties over time.
25% Indentation Force Deflection (IFD), is a measurement
of the surface feel of the foam. Support is the foam’s ability
to “push back” against weight and prevent the foam from
“bottoming out.” Higher density foam helps prevent the feeling
of having the foam collapse beneath body weight in an end use
application. Both firmness and support affect foam comfort.

There is even a measurement to determine the foam’s ability

to provide support. This measurement, support factor (also
known as compression modulus or SAC factor), is determined
by measuring the surface firmness ( 25% IFD) of the foam by
compressing a 4” thick foam sample 25 percent of its original

As a general rule, the higher the density (polymer or

overall foams), the greater the support.

SUPPORT FACTOR RANGES

2.6
2.5
2.4
2.3
SUPPORT FACTOR

2.2
2.1
2.0
1.9 Foam density is independent of foam firmness.
1.8
1.7
1.6

1.2 1.4 1.6 1.8 2.0 2.2 2.4

FOAM DENSITY (pcf)

Support factors can vary in different types of foams. Some “high performance” foam
grades are formulated to have higher support factors even at lower densities.

2 IN•TOUCH | Volume 1 | No. 2

 Research into foam COMPRESSION SET TRENDS

durability by measuring
flex fatigue, or the loss of

COMPRESSION SET
foam firmness after flexing
the foam a predetermined 15%

number of cycles, shows

10%
that as polymer density
5%
increases, firmness loss
is usually lessened. Less 2.2
1.2 1.4 1.6 1.8 2.0 2.4
firmness loss means that, FOAM DENSITY (pcf)

for example, seat cushions

and mattresses can much
SUPPORT FACTOR RANGES
of their original “feel” over extended periods of normal use.
Higher density foams also tend to retain their ability to provide
support. Other factors used to gauge foam durability can also
40%
improve as density increases. One of these is compression
IFD LOSS
30%
set, or the tendency of foam to lose thickness or height as it is
B
used. As density increases, height loss decreases dramatically, 20%

which means that the fabric on furniture cushions can remain A

taut longer and that mattresses body impressions may be less
noticeable. In fact, some mattress manufacturers use higher
density quilting foam to reduce instances of body impressions in
innerspring as well as foam mattresses.
The Role of Foam Additives and Fillers
As noted before, overall foam density can be affected by
additives and filling materials used to manufacture different
foams. In some cases, additives are used to improve the
combustion performance of
foams. For example, substantial
Foam compression
amounts of combustion- set decreases as
modifying additives may be density goes up.
needed to formulate foam
products for application in California Technical Bulletin 133
(CA TB 113) complaint furnishings. This full-scale flammability
test for finished items used in certain public occupancies calls
for components that work together to resist a very hot open-
flame ignition source. Combustion modification additives for
10%
1.2 1.4 1.6 1.8 2.0 2.2 2.4
FOAM DENSITY (pcf)
this application may increase the foam’s density by more a
pound per cubic foot. Additives also may be used to increase
foam support characteristics and to resist compression from
weight loading. Heavier weight foam can also give a seating
cushion a more luxurious feel. However, it is important to note
that while additives may increase density, and in some cases
improve support, they may not improve other properties of
the foam. Large amounts of additives can make foams more
likely to tear and can reduce foam durability. This is because
additives, since they are not part of the actual foam polymer,
can act as abrasives that break down foam cell walls. So, high
concentrations of additives can cause foam to lose more of its
original properties through use. Therefore it is important that
when you select foams for different applications, you look at the
polymer, or unfilled, density of the foam being used.

IN•TOUCH | Volume 1 | No. 2 3

 Summary
■ Density, measured in pounds per cubic foot, is a
key property for determining flexible polyurethane
foam performance.

■ Foam density is independent of foam firmness.

■ Density relates to the comfort, support and

durability properties of the foam.

■ Density can be affected by foam additives or fillers.

To truly gauge foam performance, the unfilled, or
polymer density of the foam must be evaluated.
Polymer density takes into account only the weight
of the basic fully-reacted raw materials.

■ Foam fillers and additives can be used to make the

This information is provided as a service of the Polyurethane Foam
cushion feel heavier and more luxurious, improve
Association to improve the understanding of key issues that affect
support, provide antistatic performance, reduce flexible polyurethane foam cushioning. To learn more about specific
photosensitive color change, or improve the foams, contact your foam supplier.
combustion performance of the foam, but large
This bulletin is intended to serve as a reference regarding the general properties and uses
concentrations of fillers or additives may have a of polyurethane foam and has been developed as a service for the Polyurethane Foam
Association’s (PFA) members and their customers. The information contained in this bulletin
negative effect on other foam properties. is offered in good faith, developed from sources deemed to be reliable, and believed to
be accurate when prepared, but is offered without warranty, express or implied, as to
merchantability, fitness for a particular purpose, or any other matter. The PFA and its members
disclaim all responsibility for any loss or damage arising from reliance on such information by
any party. This bulletin is not intended to be all-inclusive on any subject matter. The PFA
makes no endorsements, assurances, warranties, or guarantees concerning the quality, uses,
or applications of polyurethane foam or specific products produced from polyurethane foam.
PFA does not endorse the proprietary products or processes of any manufacturer. PFA and
its members do not assume any responsibility for compliance with applicable laws and
regulations. The PFA makes no representations regarding the combustibility of polyurethane
foam under different applications or in different formulations. It is the responsibility of readers
Visit the literature section at www.pfa.org for a complete, and purchasers or users of polyurethane foam to acquaint themselves with its combustibility
downloadable library of IN•TOUCH Bulletins. characteristics both as to usage and storage, and any questions concerning applications and
the combustibility of polyurethane foam must be directed to individual foam manufacturers
or suppliers.

© 2016 Polyurethane Foam Association, Inc. All rights reserved.

This document may not be reproduced in whole or in part without the written permission of
org

the Polyurethane Foam Association.

Published
www .pfa.Polyurethane
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thane foam
shaped, or combi
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materials. Organi
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like all organic manufacturers
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of the Polyurethane Foam Association (PFA) that covers topicsIN•TOU
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provide a specifi
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is a public polyurethane
IN•TOUCH foam.

Polyurethane Foam Association

334 Lakeside Plaza, Loudon, TN 37774
Phone (865) 657-9840 | Fax (865) 381-1292
www.pfa.org

4 IN•TOUCH | Volume 1 | No. 2