Polyurethane Sheets

Nolathane polyurethane sheets are solid sheets of engineering-grade polyurethane elastomer for making flat custom parts. Pads, washers, isolators, spacers, gaskets and wear strips can all be cut from polyurethane sheet when no ready-made part exists or when a project calls for something made to measure.

The material is the same tough, resilient type of polyurethane Nolathane uses in suspension bushings, supplied as sheet so it can be cut, punched and shaped for vehicles, trailers, machinery and workshop projects.

Solid Polyurethane Sheet vs Foam

The term ?polyurethane sheet? covers several very different products, so it?s worth being clear about which one you need:

• Solid elastomer sheet, like Nolathane polyurethane sheet, is dense, flexible and highly resistant to wear, load and oil. It?s used for engineering parts that need to cushion, isolate or resist abrasion.
• Polyurethane foam sheet is lightweight and soft, used for padding, packaging and insulation. It isn?t suitable for load-bearing parts.
• Rigid polyurethane board is a stiff insulation product used in construction.

For automotive pads, isolators and wear parts, solid polyurethane elastomer sheet is the right choice.

What Polyurethane Sheet Is Used For

Polyurethane sheet suits flat or shaped parts that need to be tough and resilient, including:

• Body, cab and tray mount pads and isolators
• Radiator, battery tray and accessory mount pads
• Spring pads, insulators and packers
• Bump pads and contact pads where parts could rub or strike
• Washers and spacers for suspension and chassis hardware
• Wear strips and chafe guards for cables, lines and moving parts
• Anti-vibration pads for engines, pumps and machinery
• Custom gaskets and seals for non-pressurised applications

For round parts with a bore, such as bushes and sleeves, polyurethane rod is usually the better starting point.

Why Polyurethane

Compared with rubber sheet, polyurethane offers:

• Outstanding abrasion and cut resistance
• High load-bearing capability without permanent flattening
• Increased tensile strength and tear resistance
• Resistance to oil, grease, ozone and weathering
• Good memory, returning to shape after compression
• Consistent performance across a wide range of temperatures

Nolathane has been making polyurethane suspension bushings since 1974, originally developed to replace brass bushes in hillclimb competition. Decades of experience with polyurethane under real-world loads is why it?s a trusted material for custom pads and isolators.

Choosing Durometer and Thickness

Polyurethane sheet is made in different hardness grades, measured on the Shore A durometer scale. Softer grades absorb more vibration and suit isolators and comfort-related pads. Harder grades resist compression and wear and suit spacers, packers and high-load pads.

Thickness matters too. Thicker sheet provides more cushioning and more travel under load, while thinner sheet suits washers, shims and wear strips. Each listing shows the durometer and dimensions of the sheet.

Cutting and Shaping Polyurethane Sheet

Polyurethane sheet can be shaped with common workshop tools:

• Straight cuts: use a sharp utility knife with several passes on thinner sheet, or a bandsaw on thicker sheet
• Curves and profiles: use a bandsaw, jigsaw with a fine blade, or have the sheet waterjet cut for complex shapes
• Holes: use a hole punch or sharp hole saw at low speed, as heat can cause melting and rough edges
• Lubrication: a little soapy water on the blade helps knives and saws cut cleanly
• Finishing: trim rough edges with a sharp knife or a light sanding

Mark parts with a fine marker and a template, and cut slightly oversize before trimming to the final shape.

Fixing Polyurethane Parts in Place

Polyurethane is difficult to bond reliably with many common adhesives, so mechanical fastening is usually the best approach. Clamp pads between components, use bolts with large washers, or locate parts in a recess or channel. Where adhesive is required, use one designed for polyurethane elastomers and prepare the surfaces carefully. Avoid over-tightening fasteners through polyurethane pads, as excessive compression shortens their life.

Designing Custom Pads and Isolators

A few principles help custom polyurethane parts perform well:

• Spread the load over the largest practical area to avoid point loading
• Use steel washers or sleeves where bolts pass through, so the pad isn?t crushed
• Allow room for the material to bulge slightly when compressed
• Choose a softer grade for vibration isolation and a harder grade for location and spacing
• Keep pads away from exhaust heat and other high-temperature sources

Fitting and Inspecting Custom Parts

Before final fitting, check that each custom part sits flat and evenly, with no sharp edges or burrs on the mating surfaces that could cut into the polyurethane. Clean any oil or grit from the mounting faces, then position the part and tighten fasteners evenly so the load is shared across the whole pad.

After fitting, inspect custom pads and isolators after the first few hundred kilometres or operating hours. Look for signs of movement, cracking, excessive bulging or wear where parts rub. If a pad is compressing too much, a harder grade or thicker sheet may be needed. If vibration is still being transmitted, a softer grade may work better. Keep a note of the grade and thickness used so successful parts can be repeated.

Limitations to Keep in Mind

Polyurethane sheet is versatile, but it isn?t a structural material and shouldn?t replace metal brackets or load-carrying parts. It can soften at very high temperatures, and harder grades transmit more vibration than rubber. For safety-critical suspension and steering positions, a purpose-designed vehicle-specific part is always the first choice where one exists. Custom gaskets made from sheet suit low-pressure, non-critical applications only.

Who Polyurethane Sheet Suits

• Classic and vintage vehicle restorers recreating pads and isolators that are no longer made
• 4WD and ute owners fitting trays, canopies, drawers and accessories
• Custom and modified vehicle builders
• Motorsport teams and engineers making one-off parts
• Workshops, fabricators and DIY users working on vehicles, trailers and machinery

Shop Polyurethane Sheets

Flat polyurethane stock for custom pads and spacers sits in Nolathane's universal parts range.

Choose the durometer and size to suit your project, then order online with fast shipping or pick up from a Nolathane reseller. 60-day returns give you time if a product isn?t right, and our local support team can help you choose a suitable grade, whether you?re making custom pads for a restoration, isolating a tray or canopy, or building a one-off part in the workshop.