One-Piece Chair Shell Is Integral-Skin PUR Foam

What appears to be the first chair shell molded in one piece of self-skinning polyurethane was recently unveiled by Italian furniture manufacturer Fratelli Rossetto.

What appears to be the first chair shell molded in one piece of self-skinning polyurethane was recently unveiled by Italian furniture manufacturer Fratelli Rossetto. The very light Free Form seat of the new designer chair has a half-shell shape produced with Bayflex 20/30 from Bayer MaterialScience (U.S. office in Pittsburgh), a soft, elastic foam with a closed outer skin and cellular core. The integral-skin foam reportedly absorbs mechanical stresses very well, is extremely comfortable and pleasant to the touch, resists scratches and household chemicals, and is easy to clean. Moreover, the flame-retardant foam meets Italian FR standard CSE RF 4/83 and its low density—250 kg/m3 (15.6 pcf)—is said to allow for cost-effective production. There is no color restriction. An in-mold coating process applies a special coating the side of the mold that creates the aesthetic surface of the part. The mold is then closed and the foam system is injected.