Battle-Tested

Spray Foam Magazine – Spring Issue 2025 – Polyurethane chemistry has virtually endless incredible uses, from sponges and surfboards to boat decks and bowling balls. Still, some that I find most fascinating, other than spray foam insulation, of course, are its uses in military applications. From slowing down bullets to blood loss, let’s explore some of the many uses of polyurethane chemistry in the military.

Ballistic Resistant Foam

Nothing is genuinely bulletproof, but polyurethane foam has excellent physical properties that help reduce damage and injury from gunfire, shrapnel, and blasts. Because polyurethane chemistry is easily customizable, polyurethane, at higher densities than spray foam, can be designed based on the application or hazard to protect from ballistic shock waves to vehicle collisions. Polyurethane can be used with other projectile-resilient materials, such as Kevlar or polyethylene, to create vests, body armor, and vehicle armor.  

Floatation

Polyurethane foam can be sewn into a tactical vest to aid in flotation that military, police, and other service and rescue personnel can wear. It doesn’t stop with personal floatation. In the article “Does it Float?” from the Summer 2024 issue of Spray Foam Magazine,we learned how polyurethane foam can be poured or sprayed into boats to increase their buoyancy or seal cavities so they will remain afloat. This, of course, extends to military applications as well.  

Military-grade vehicle parts

Polyurethane is used to make all sorts of parts for military vehicles. Bumpers, ring seals, shock absorbers, coatings, gaskets, rods, bushings and many more parts can be manufactured out of polyurethane and made specifically for military applications. Polyurethane outperforms other materials in extreme climates and temperatures and is very chemically

resistant. It can also be used to extend the life of metal, for example, as a coating or as a sheet that can be adhered to its surface.

Padding and Protection

Polyurethane pads and cushions can be used all over the body for protection from impacts and lacerations in helmets, vests, uniforms, rifle recoil pads, knee and elbow pads, and boot soles. With varying design strengths, it can be tailored for many applications. Additionally, it is lightweight, breathable, and offers exceptional durability.

Insulation

This is not a surprise to the spray foam community, but it would be irresponsible not to mention how valuable polyurethane foam insulation is to the military in creating livable environments in many extremely uncomfortable climates. It can be installed quickly over various surfaces, creating an insulated space protected from extreme heat or cold, humidity, high winds, and torrential rain. Because it comes in compact containers and has a high R-value per inch, its compactness is well suited for military operations.

Soundproofing

Polyurethane’s flexibility and recovery allow it to absorb sound vibrations, and its ability to air-seal can prevent noise from penetrating walls. Military vehicles, ships, and aircraft can create noise levels that are beyond safety standards, plus excessive noise levels can make important and critical communication impossible. Spray polyurethane foam can be used to separate engine compartments, road noise, and runway noise from passengers and occupants in nearby buildings.

Coatings

Like spray polyurethane foam roofs and vessels, the military has discovered uses for polyurethane as a protective coating. Polyurethane coatings have excellent wearability and versatility for extreme exterior applications over aircraft, aerospace equipment, and marine vessels. It’s chemical resistant, compatible with many surfaces, and has been proven to protect against extreme weather, humidity, and salt spray.

Packaging

Military equipment is some of the most high-tech, specialized, and valuable products being used today and must be protected in the most efficient way possible. As in industrial applications, polyurethane foam is an excellent product that will protect valuable equipment during shipping when designed to expand to the correct physical properties. Creating foam protective packaging is quick; it can form into any shape and is lightweight and compact. These attributes of polyurethane package foam are essential qualities for military shipping applications.

Blood Stopping

There are several companies in various iterations of research, testing, and approval creating a polyurethane foam product aimed at saving lives on the battlefield. A common cause of death during battle is the type of internal bleeding that cannot be stopped by standard direct pressure techniques that use gauze or tourniquets. These are typically injuries sustained in the torso region. Scientists are developing a polyurethane foam that can be injected into deep wounds in the field to slow bleeding in that critical first hour before victims can receive medical treatment. When the 2-part polyurethane foam is injected into the wound, it quickly expands and begins to slow down the bleeding. In 2019, the FDA gave a Breakthrough Status Designation to a company developing a foam for this use. This Breakthrough Status Designation helps accelerate the development of novel life-saving technology.

Polyurethane remains one of the most versatile products used for countless applications. Its lightweight, customizable, moldable, strong, and durable properties make it a unique product that can be used in almost every application and industry, making it an essential product for the military.  

References

1. Johns Hopkins University. "Injectable foam could prevent fatal blood loss in wounded soldiers." ScienceDaily. July 10, 2014. www.sciencedaily.com/releases/2014/07/140710111523.htm

2. PR Newswire. “Breakthrough Device Designation received from the FDA.” June 18, 2019. https://www.prnewswire.com/news-releases/breakthrough-device-designation-received-from-the-fda-30086...