Polyurethane Foam
ATD Polyurethane Foam Service Bulletin
Publication Date: August 13, 2010
Overview
A minor change to the chemicals used in the polyurethane foam process is being implemented
Background
Polyurethane foam is used to manufacture many dummy parts – such as arm and leg flesh, pelvises, jackets, and neck shields. Polyurethane is specified on many regulated drawings and is made from a two part liquid material that reacts and expands when the two components are combined. First Technology Safety Systems (FTSS) and Denton ATD (DATD) meet the requirements of the drawing package with respect to Polyurethane Foams.
Current Standard
FTSS has been informed by its supplier that the raw materials needed to manufacture its polyurethane foam recipes are no longer available. Due to the unique nature of the raw materials used in this process, the FTSS supplier has decided to stop supplying these ingredients. The Denton ATD Brand is not affected by this issue since DATD has a separate supplier of polyurethane foam materials and has a different material recipe.
Challenge
Material specification gaps currently exist for the polyurethane foams identified in the regulated drawings. Due to these information gaps FTSS and DATD have identified part stiffness as a significant variable between the two brands. Humanetics believes that the variations in part stiffness can be attributed to the polyurethane formulations used by each brand.
Summary of Improvements
To overcome these material specification gaps, Humanetics will add a stiffness equivalency criterion to our drawings that go beyond the minimum material specifications found in the current drawing packages. We are currently running tests to evaluate the various polyurethane foams found in both brands, so that a stiffness specification can be established. Once the stiffness specification is established, we will be able to utilize the DATD brand foam as a replacement for the obsolete FTSS foam. By adjusting the foam recipe and testing the foam to the new stiffness specification, we will be able to ensure that the current “feel” of the FTSS Brand is maintained.
Conclusion
Due to the obsolescence of the raw materials used to manufacture the FTSS Brand polyurethane foam, FTSS is currently running validation tests on the DATD foam for use as a direct replacement. DATD has a qualified polyurethane product that meets regulated drawing specifications and Humanetics is confident that this foam can be used as a direct replacement with respect to fit, form and function.