Porous Foam Expertise for Medical & Cosmetic Applications
Open-cell porous foam is manufactured by Porex using proprietary or customized blends of raw materials through a clean polyurethane process that does not use catalysts. Various formulations can offer wide-ranging densities, porosities, and levels of softness available with application-specific additives including antimicrobials, nanomaterials, pharmaceuticals, botanicals, cosmetic ingredients, and colorants that can enhance your device’s look, functionality, and performance. Porex’s porous foam types include both medical-grade (ISO 10993-certified) and cosmetic foams, with pore sizes ranging from 90 microns to over 350 microns.
![Open Cell Foam](https://www.porex.com/wp-content/uploads/2019/09/OpenCellFoam_425x425.jpg)
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Manufacturing process
Polyurethane foam materials can be manufactured using two different processes: a conventional “one-shot” process – like you see in furniture and car seat cushions – or as a two-step prepolymer process. During a one-shot approach, all ingredients are simultaneously mixed and poured onto a conveyor, a trough, or a mold, where it is allowed to react, expand and cure. While this process does promote high throughput, it does not lend itself to customization, as cell structures are non-uniform. For application-specific devices, Porex’s two-step process, as highlighted below, allows for the creation of customizable, omnidirectional pores that can promote faster wicking, higher absorption, and excellent retention in both advanced medical and cosmetic applications.
![](https://www.porex.com/wp-content/uploads/2023/05/porous-foam.png)
Step 1: Isocyanate, polyol, and/or other ingredients are mixed in a certain stoichiometric ratio to make a prepolymer
Step 2: Prepolymer activated with an aqueous solution containing primarily water.
Step 3: Continuous foaming process from reaction, rising, curing, and drying.
Options for customizing porous foam
![Open Cell Foam](https://www.porex.com/wp-content/uploads/2019/09/OpenCellFoam_425x425.jpg)
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Common applications for porous foam
![absorption function](https://www.porex.com/wp-content/uploads/2019/09/Absorbtion_outline_0.png)
Absorb
Porous foam material can be used in a number of applications requiring absorption such as patient positioning and surgical support as well as PPE face masks and advanced wound care medical-grade foam. Because it is biocompatible, hypoallergenic, and can be customized for softness, it is a good candidate for skin contact.
![Application Solutions](https://www.porex.com/wp-content/uploads/2019/09/Application-outline.png)
Apply
For topical skin adhesives or cosmetic makeup sponges, porous foam material can allow for the delivery of precise amounts of liquid, creams, or powder-based foundations without irritating the skin. Porous foam can enable reusability and be made from a bio-based polymer for a more sustainable applicator.
![Filtration solutions](https://www.porex.com/wp-content/uploads/2019/10/Filtration_outline.png)
Filter
Filtration properties allow for therapeutic techniques such as using a suction dressing to remove excess exudation while treating acute or chronic wounds or highly sensitive second and third-degree burns. Foam allows the wound edges to be drawn together, reducing the chance of edema and infections. Adding a carbon additive can also help with odor.
![Porous Laboratory Components](https://www.porex.com/wp-content/uploads/2019/10/PorousPolymer-2-1800x500.jpg)
Why do pore size and flow matter?
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Related Resources
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