One of the essential factors in prostheses is their fitting. To assemble a prosthesis with the residual limb, so-called liners are used. Liners used currently are criticized by users for their lack of comfort, causing excessive sweating and skin irritation. The objective of the work was to develop viscoelastic polyurethane foams for use in limb prostheses. As part of the work, foams were produced with different isocyanate indexes (0.6–0.9) and water content (1, 2 and 3 php). The produced foams were characterized by scanning electron microscopy, computer microtomography, infrared spectroscopy, thermogravimetry and differential scanning calorimetry. Measurements also included apparent density, recovery time, rebound elasticity, permanent deformation, compressive stress value and sweat absorption. The results were discussed in the context of modifying the foam recipe. The performance properties of the foams, such as recovery time, hardness, resilience and sweat absorption, indicate that foams that will be suitable for prosthetic applications are foams with a water content of 2 php produced with an isocyanate index of 0.8 and 0.9.

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Polyurethane foams are widely used in biomedical applications due to their desirable mechanical properties and biocompatibility. However, the cytotoxicity of its raw materials can limit their use in certain applications. In this study, a group of open-cell polyurethane foams were investigated for their cytotoxic properties as a function of the isocyanate index, a critical parameter in the synthesis of polyurethanes. The foams were synthesized using a variety of isocyanate indices and characterized for their chemical structure and cytotoxicity. This study indicates that the isocyanate index highly influences the chemical structure of polyurethane foams, also causing changes in cytotoxicity. These findings have important implications for designing and using polyurethane foams as composite matrices in biomedical applications, as careful consideration of the isocyanate index is necessary to ensure biocompatibility.

This article presents the results of testing foam blocks made with a high-pressure foaming machine under industrial conditions. Foam blocks were made at pressures in the range of 110–170 bar with substrate temperatures allowed by machine suppliers. The foaming process parameters of each block were evaluated. The structure of the foams in the outer and central parts of the blocks was characterized using FTIR spectroscopic analysis and microscopic observations using SEM. The changes in apparent density, strength properties and brittleness of the foams were evaluated. The properties of the blocks made at different mixing pressures varied depending on the pressure at which the substrates were mixed and the location in the block. The biggest differences that were observed were the friability of the foams taken from different locations in the blocks by up to about 30%; the apparent density differed by about 8% and the compressive strength by about 5%.

Components for manufacturing polyurethane foams can adversely affect the human body, particularly if they are in contact with it for long periods. In applications where the foam is not placed directly into the body, the study of the product’s effects is often neglected. In the case of human skin, distinguishing the increasingly frequent problems of skin atopy, more attention should be paid to this. This paper presents the influence of the different catalytic systems on cytotoxic and thermomechanical properties in polyurethane foams. Among others, foams were produced with the most popular catalysts on the market, DABCO and a metal-organic tin catalyst. The foams were characterized by thermomechanical properties and were subjected to a cytotoxicity test against human keratinocytes. In biocompatibility tests with skin cells, the results were highly variable. VAB 2 with a catalytic system consisting of commercial Diethanolamine and Addocat®105 performed the best. However, with such a catalytic system, the mechanical properties have worsened.