PU: Everything You Need to Know About This Material - EKI

What is polyurethane foam?

Polyurethane is an umbrella term for various polymers that can be applied in many ways, but what is polyurethane and how is it created? The material polyurethane is formed by the polymerization reaction between a soft polyol and a hard isocyanate. It is a very strong, wear-resistant, and highly flexible material. When gas is added during the polymerization process, the polyurethane starts to foam. At that point, polyurethane foam is created.

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Which characteristics does polyurethane foam have?

Foam made from polyurethane is called PU foam, polyether foam, or polyurethane foam. This material is very soft and flexible. There are different types of PU foam: hard and soft types. All have an open cell structure, which gives the material good mechanical properties, allowing it to be easily compressed and then return to its original shape.

PU foam is available in various hardnesses and densities. Generally, the higher the density, the more durable and comfortable the foam is. Besides comfort, it can also be used for sound absorption. Furthermore, the material is well-resistant to aging when used indoors. However, a drawback of the material is that it has a shorter lifespan compared to other foams. The estimated lifespan of PU foam is about five to ten years. Exposure to direct sunlight and outdoor use can shorten its lifespan. If you are looking for a foam that lasts longer and can withstand direct sunlight, PVC foam might be a better choice.

In which products from EKI is polyurethane foam used?

EKI offers a wide range of different polyurethane foams. With us, you can find products such as PU tape, pyramid foam, PU foam blocks, convoluted foam, PU foam sheets, compression tape, and PU back padding. Our products are available in the colours anthracite and white and come in various hardnesses, densities, and sizes. We cut our large foam blocks into usable formats such as rolls, sheets, blocks, tapes, discs, and rings. Virtually all desired shapes are available. Most shapes can be supplied with single-sided or double-sided adhesive. The pyramid sheets and convoluted foam are only available with single-sided adhesive. Back padding is only supplied non-adhesive.

The polyurethane (PU) manufacturing process in the skateboarding industry has long intrigued me, particularly regarding claims of proprietary formulas.1 While companies proudly advertise their unique compounds, I’ve grown increasingly skeptical about the extent of their chemical innovation. My suspicion stems from a simple observation: polyurethane itself is likely produced in just a handful of massive industrial plants worldwide, with fixed formulas. What skateboarding companies actually do, I believe, is purchase this raw material in bulk and process it into skate products. The notion that small-scale companies could have the capacity to produce their own polyurethane from scratch seems implausible. Are they truly creating novel formulas, or simply selecting from existing options and adding their branding?

This question led me to an enlightening forum discussion with Zipzit, an engineer from Las Vegas, who brought valuable manufacturing insights to the table. Our exchange revealed the complex reality behind PU product manufacturing and raised important questions about innovation in the skateboarding industry.

“What baffles me,” I began, “is how small manufacturers claim to have original, unique formulas that somehow make their wheels both harder and softer simultaneously. How do they develop these formulas, and if they’re truly innovative, why aren’t they patented?”

Zipzit’s response was revealing. “Patent the formula? Why do that?” he countered. “Filing a patent requires disclosing all details, making it easy to clone. As the patent holder, you’d need to prove theft and pursue legal action globally – a costly endeavor in lawyer fees alone. It’s more practical to keep the secret and work with trusted manufacturers.”

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He outlined two paths for entering the market: either partnering with existing manufacturers to produce parts to specification or investing in complete manufacturing infrastructure – molds, cooling racks, curing ovens, finishing lathes, and warehouse space. This explanation helped clarify why smaller companies might stick to simpler products like bushings rather than venture into wheel production.

When I pressed about the actual chemistry involved, wondering if it was more akin to mixing e-liquids than serious chemical engineering, our discussion turned to the industry’s broader state. Zipzit shared his experience visiting a major wheel manufacturer in Southern California, describing impressive quality control processes and testing procedures. He painted a picture of an industry more sophisticated than I’d imagined, where niche skateboarding businesses often emerge as side projects from mainstream manufacturing operations.

Notably, while Zipzit emphasized the technical capabilities of these operations, he never contradicted my fundamental suspicion – these companies were still working with the same base polyurethane materials from major chemical manufacturers, not creating their own from scratch. Their sophistication lay in processing and testing, not in fundamental chemistry.

“Outside one or two companies, we see no new ideas – just aggressive marketing,” I argued. “The market is shrinking, and skateboarders are aging. Younger people are looking elsewhere, partly because the industry hasn’t inspired trust that it takes itself and the sport seriously.”

This tension between Zipzit’s optimistic view of manufacturing capabilities and my concerns about industry stagnation highlights a crucial debate within skateboarding. While some companies like G|Bomb demonstrate genuine innovation and engineering rigor, others seem content with minimal advancement, relying instead on marketing claims and brand identity.

The reality likely lies somewhere between these perspectives. The technical capability for sophisticated PU manufacturing exists, as Zipzit’s manufacturing experience confirms. However, the industry’s willingness to invest in meaningful innovation and transparency about their processes remains questionable. The future of skateboarding as a transportation option may depend on whether companies can bridge this gap between potential and practice.

Perhaps most telling is the industry’s reluctance to share findings about their products’ characteristics – a stark contrast to bicycle tire manufacturers who regularly publish detailed performance data. This opacity, combined with sometimes dubious marketing claims, suggests that while the technical capacity for innovation exists, the industry’s approach to development and communication may need to evolve to ensure its long-term relevance.

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