Liquid SunMate® FIPS
Revision: 3
effective date: 150519
INSTRUCTION MANUAL
Liquid SunMate FIPS
®
Foam-In-Place Seating
ATTENTION
The Liquid SunMate FIPS system may be used only by those who have completed the
required training in safe product handling and use. Training consists of watching the FIPS
Instructional Video AND reading this manual. Understanding of the training material must be
verified with Dynamic Systems, Inc. (DSI) by the user before the product will be shipped. A
Verification Statement of Training is included in this manual. Complete and fax, mail or e-mail
the form to DSI. Once we have your statement on file, you may order as often as you like.
®
NASA and U.S. Space Foundation Space technology Hall of Fame inductee
engineered by Flexible Polyurethane Foam Hall of Fame inductee, Charles A. Yost
CS-d7
Contents
1 Introduction
2 Basic Training
3 Molding Process at a Glance
4 Packaging Options
5Support Pressure Options
6Safety and Handling
7 Before You Pour
10 Molding a Custom Seat Cushion
with the FIPS Bag Pack
12 Molding a Custom Back Cushion
with the FIPS Bowl Pack
14 Finishing the Cushion
16 Waterproofing
17
Appendix A
Custom Sizes
Fire Safety Options
How to Dispose of Expired Chemicals
18 Appendix B
Reading Labels
19 Appendix C
Iso Safety
20 Appendix D
Cold Weather Heating Instructions
21 Verification Statement of Training
104 Morrow Branch Rd., Leicester, North Carolina 28748 USA
Toll Free 855-786-6283 Toll Free Fax 844-270-6478
E-mail [email protected] www.sunmatecushions.com
Liquid SunMate® FIPS (Foam-In-Place Seating) Instruction Manual
Published by Dynamic Systems, Inc. © 2015 All rights reserved.
SunMate® and Liquid SunMate® are registered trademarks of Dynamic Systems, Inc.
Introduction
Award-Winning Technology
Dynamic Systems, Inc. (dsi) began research in 1969 to perfect
foam cushion materials having both high energy absorption
and soft pressure properties. In cooperation with nasa, dsi
researched the application of the newly-developed materials for
aircraft ejection seats and airline passenger seats. The technology soon expanded to provide seating systems for the severely
disabled. More than four decades later, DSI continues to produce
one of the most affordable advanced cushion materials available
for support, comfort, and energy absorption.
In 1998, dsi was inducted into the U.S. Space Technology Hall
of Fame for the successful development and commercialization
of this seating technology. In May 2015, DSI's founder, Charles
A. Yost, was inducted into the Flexible Polyurethane Foam Hall of
Fame. Company growth and strength are a direct result of exceptional customer service, product quality and performance.
Liquid SunMate® FIPS (Foam-in-Place Seating)
Liquid SunMate® FIPS was developed in 1984 for wheelchair
users with complex seating and positioning needs. Today the
three-chemical, mix-and-pour, direct custom-contouring system is
used most often to create seat, back, or total cushion inserts for
advanced posture control. Liquid SunMate® FIPS is used to mold
custom seats for motorsport vehicles, boats, aircraft, and many
other applications requiring custom-molded parts.
The Molding Process
To make a cushion, the Liquid SunMate® FIPS ingredients are
mixed in sequence and poured into a molding bag placed in
a wheelchair or on another seating surface. The person to be
molded is positioned on the bag, and the liquid foam rises and
forms around the body within minutes. After the foam has cured,
the cushion is finished with detail trimming, soft laminate, and
protective fabric. Waterproofing is optional. The entire process
can be completed in 2-4 hours depending on the cushion's size
and contour complexity.
Cushion Properties
cushion materials developed and manufactured
by dynamic Systems, Inc.
SunMate®
polyurethane viscoelastic foam available in 8 levels of pressure support
(cushions, sheets, wedges, buns, or shredded)
SunMate® FRG
SunMate® containing a non-halogenated fire-retardant additive
Liquid SunMate® fips (Foam-In-Place Seating)
direct mold, custom-contouring seating system
Pudgee™
gel-like cushion with very low shear force and cooling properties
Laminar™
dual-layer composite cushion combination of SunMate® and Pudgee™
Laminar III™
tri-layer composite cushion combination of SunMate® and Pudgee™
Contour Laminar™
Laminar™ with built-in generic contour
Comfort Foam
extraordinarily soft memory foam
other products offered by dsi
Waterproof Coatings
Fire Retardant (FRG) Additive for Liquid SunMate® FIPS Bowl Pack
Liquid SunMate® FIPS Accessories
Cushion Slipcovers and Fabrics
waterproof, velour, and stretch-knit
A finished cushion has the same exceptional qualities as
SunMate®:
• slow springback, high-density, high-resilience
• flows to match body contours and slowly returns to its original
shape once pressure is removed
• open-cell structure to maximize airflow to reduce heat buildup
• uniform pressure distribution and impact energy absorption to
alleviate sitting fatigue
• a wide range of pressure supports to support any weight
distribution need
• effective within a temperature range of -20°f to 150°f
• passes California Technical Bulletin #117, Section D, Part II
without the use of fire-retardant additives, coatings or fabrics
Medical Professionals Choose FIPS
Orthopedic professionals, therapists and seating specialists use
Liquid SunMate® FIPS to:
• slow progressive deformities, address fixed deformities or
excessive tone problems
• improve body functions and blood circulation by distributing
sitting pressure evenly
• relieve pressure points, soreness and fatigue associated with
confined or prolonged seating
• control body positioning with the gentle fixed support
Safe, Versatile, and Inexpensive
In a fire, a FIPS cushion burns with inherently low levels of toxicity
because natural plant ingredients constitute 33-42% of its makeup. This adds safety and a sense of freshness unique to SunMate®.
Liquid SunMate® FIPS was designed to be easy to transport,
use, clean up, and proportion for custom sizes. It may be used
with almost any open-mold design; and is one of the most
affordable custom-molding systems on the market.
Time-Tested Quality and Reliability
Liquid SunMate® FIPS has been tested, proven and accepted
by orthopedic and medical professionals worldwide for over 30
years. Dynamic Systems is ISO 9001:2008 certified, so quality is
guaranteed for each product before it leaves the plant.
Liquid SunMate® FIPS Instruction Manual 1
Basic Training
1
/3 unit, 1%
For your safety and the safety of the client, a basic understanding of the product and its use is required
and must be verified with Dynamic Systems before your first order for Liquid SunMate® FIPS will be
1 / unit,
unit,
shipped. Basic training is achieved simply by reading this manual and watching the
training/ 13%
video.
16%
1
1
2
Bag Pack,
34%
Instruction Manual and Training Video
Bowl Pack,
By carefully reading this manual, and watching the liquid
66%
®
sunMate FIPs training video, you will gain a thorough
understanding of the entire foam-in-place process including
important safety information, illustrated step-by-step instruction,
finishing techniques, and tips for achieving the best results.
Additional copies of this manual are free and may be
Bowl vs. Bag
Customer
Preference
requested or downloaded online. The 20-minute video may
be
viewed online or on DVD, and includes bonus footage of the
seating team at CarePartners Wheelchair Clinic in Asheville, nC,
Semi-rigid, .4%
making a custom back cushion for a young client. Med-firm, .6%
Extra
Once you have read the manual and watched the video,
soft
complete and return to Dynamic Systems the Verification
6%
statement of training (located in the back of this manual.) Once
Medium
®
the form is on file, your first order for Liquid SunMate FIPS will25%
be shipped and you may continue to order as often as you like.
Contact information on this form must be updated every 2 years.
Practice with an Introductory Kit
2
Med-soft
2%
Full unit,
70%
Unit Sizes Ordered
Soft, 66%
We encourage anyone new to the product to practice first using
the Liquid SunMate® FiPS Instructional Video filmed at CarePartners
the Liquid SunMate® FIPS Introductory Kit. The kit comes with
Wheelchair Clinic in Asheville, NC, features a pour for a young wheelchair
all the materials necessary to make one custom-molded seat or
client using a fabric-finished mold-in-bag back.
Support
back cushion. This is an excellent way to become familiar
with Pressure Order Trend
the process before molding an insert for a client.
Art/Architecture .5%
The Introductory Kit includes:
Private
Agency:
4%
• 1 unit of Liquid SunMate® FIPS (your choice of packaging
Therapist, Individual, Prothetics: 8%
and formulation)
®
• 1 16" x 37" x ¼" SunMate laminate
Race Car, Motorcycle,
Specialty, Veterinary: 10%
• 2 16" x 18" x 1" SunMate® base cushions
Rehab Center,
School,
• 2 pair of disposable gloves
Nursing Home,
• 2 molding bags (1.4 mil, 33 gal)
Hospital,
• 1 pair of safety glasses
Other Medical:
• 1 Instruction Manual
Medical Dealer/Distributor, OEM: 38%
38%
(Fabric/waterproofing materials not included.)
Workshops and Demonstrations
Liquid SunMate® FIPS demonstrations are often given at medical seating conferences in the U.S. and abroad. Special courses
are sometimes offered by therapists, seating specialists and
dealers who work with our products. If you would like to attend a
workshop or see a product demonstration, contact DSI for more
information.
orDerInG reQuIreMent
As a safety precaution, before your first order for FIPS will be shipped, you must:
1. Watch the liquid sunMate® FIPs training video (available online or on dVd),
2. read this Instruction Manual, and
3. sign and return the VerificationStatementofTraining to dSi.
2
LiqUid SUNMAte® FiPS iNStRUCtioN MANUAL
FIPS Customer Demographics
Molding Process at a Glance
Liquid SunMate® FIPS is a versatile product and can be used in a wide variety of applications including
aircraft, race car and motorcycle seating. However, the vast majority who order FIPS use it primarily for
medical applications and wheelchair seating. The three most common molds created are for a seat
cushion, a back cushion or a total chair insert which includes both the seat and back support.
IMPORTANT: BASE CUSHIONS
Liquid flows to areas of least resistance so Liquid SunMate® will not flow where the client’s body meets the seating surface
at the highest pressure points. Therefore, it is essential to place SunMate® base cushions inside the molding bag onto
which the liquid will be poured. The liquid binds to the base cushions which become an integral part of the mold. This
provides support where the liquid cannot go.
The thickness and pressure support (Soft, Medium, etc.) of the SunMate® base cushion(s) is determined by the therapist
or seating specialist. A thickness of at least 1" is recommended to prevent bottoming-out.
Making a Seat Cushion
First, the molding bag, with SunMate® base cushions inserted,
is placed on the seat of the chair. The Liquid SunMate® is mixed
and poured into the molding bag. The client is then quickly transferred to the chair, seated on the bag, and gently held in position
while the liquid foams around the body’s contour. After the cushion has set (about 5 minutes), it can be removed for finishing.
Making a Back Cushion
First, the molding bag, with SunMate® base cushion inserted,
is placed against the back of the chair, and the client is seated
in front of it. The client leans forward while the Liquid SunMate®
mixture is poured into the molding bag. The client then leans
back and is gently held in position while the liquid foams around
the contour of the client's back. After the cushion has set (about
5 minutes), it can be removed for finishing.
Molding Bag
Molding Bag
SunMate® Base Cushion
Inside Molding Bag
SunMate® Base Cushions
Inside Molding Bag
Making a Total Insert
First, the seat cushion is made as described above left. Once the foam cures, it is removed from the chair, the excess is trimmed, and
it is placed back in the chair.
Next, the client is seated and the back cushion is made as described above right. Once the foam has set, the excess is trimmed
and any adjustments are made. The seat and back inserts are glued together, covered with a soft SunMate® laminate and fabricfinished to form a total chair insert.
Molding Bag #1
1
SunMate® Base
Cushions Inside
Molding Bag
Molding Bag #2
3
2
SunMate® Base
Cushion Inside
Molding Bag
4
Seat
Insert
A detailed description of the process begins on pg. 10.
Liquid SunMate® FIPS Instruction Manual 3
Packaging Options
Liquid SunMate® FIPS comes packaged in either a Bowl Pack or a Bag Pack. With the Bowl Pack system,
the chemicals are combined in a mixing bowl (included). With the Bag Pack system, the chemicals are
mixed directly in the foil bag. Both methods produce the same result, but have different advantages.
Liquid SunMate® FIPS Bowl Pack
The Bowl Pack consists of 3 individual containers of premeasured chemical ingredients, each labeled with safety and
handling instructions.
First, the Polyol and Catalyst are combined in the mixing bowl
and thoroughly mixed with an electric beater for 2 minutes. Next,
the Iso is added and mixed on high speed for 15 seconds. The
mixture is poured into the molding bag, and quickly, the person
to be molded sits upon or leans against the bag while the foam
rises and forms a solid cushion around the body. It takes about 5
minutes for the foam to rise and cure.
The Bowl Pack Advantage: It is easy to visually check the
chemicals' consistency through the translucent containers
and assess thorough mixing in the bowl.
Liquid SunMate® fips Bowl Pack
Liquid SunMate® FIPS Bag Pack
The Bag Pack is a unique, 3-compartment, foil-laminate bag. Each ingredient of Liquid SunMate® FIPS is
contained in a separate, sealed section of the bag.
To combine and activate the ingredients, the separation clips are removed in sequence and the bag is
vigorously massaged and shaken to achieve a uniform mixture.
Mixing times and instructions are conveniently printed on the bag.
The Bag Pack Advantage: No mixing utensils are required. The
process is clean and generates very little waste – just throw the
bag away after all the ingredients have reacted. This method is
fast, neat, efficient, and easy to transport.
Bag Pack,
34%
Liquid SunMate® fips Bag Pack
Ordering Trends For FIPS
1
11/2 unit,
16%
/3 unit, 1%
1
/2 unit,
13%
Bag Pack,
34%
Unit Sizes and Applications
Pack,
Liquid SunMate® FIPS comes packagedBowl
in the
following standard
66%
sizes: one-third, one-half, one, and one-and-a-half units. Chemicals also may be ordered separately or in bulk.
Some typical applications are described below. Mixing order
and times are the same for all unit sizes. See Appendix A (pg. 17)
vs. Bagmolding.
for help apportioning chemicalsBowl
for custom
Customer Preference
Med-firm, .6%
Semi-rigid, .4%
Bowl Pack,
66%
Full unit,
70%
Bowl vs. Bag
Customer Preference
Unit Sizes Ordered
Med-firm, .6%
Extra
soft
6%
Medium
25%
Medium
25%
Med-soft
2%
Semi-rigid, .4%
Extra
soft
6%
Soft, 66%
Med-soft
2%
Soft, 66%
1
11⁄2 Support
units and
Bulk Liquids
⁄3 and 1⁄2 units
1 full unit
Pressure
Order Trend
Support Pressure Order Trend
A 1½ unit size is good for larger molds
A full unit size contains enough liquid to
Fractions of a unit are great for making
such
make one adult seat cushion or one
adult
small molds such as headrests, arm
Art/Architecture
.5%as a high-back wheelchair cushion
or a total wheelchair insert for a child.
back cushion.Private
The back
mold
Private Ag
troughs, lumbar supports, etc. The mold
Agency:
4% shown
Several units may be used
for a complex
above
was poured
inside
shown above was made for a shoulder Therapist,
Therapist,
Individual, Prothetics
Individual,
Prothetics:
8% a fabric-finished
mold like the full-body cushion shown
molding bag.
prosthesis.
above.
Race Car, Motorcycle,
Race Car, Motorcycle,
4 Specialty, Veterinary: 10%
Liquid SunMate FIPS Instruction Manual
®
Rehab Center,
School,
Nursing Home,
Hospital,
Other Medical:
Specialty, Veterinary: 10%
Support Pressure Options
Liquid SunMate® FIPS is available in three standard formulations: Soft, Medium, and Semi-rigid. Choose
the level of support to match the client’s needs. Formulations are color-coded for easy identification, but
can also be ordered without pigment for a white cushion. Soft (pink)
Semi-rigid (light green)
Medium (blue)
The Soft formula offers greater immersion
and low pressure support. It is noticeably
softer and more elastic than the Medium
formulation. Choose Soft to cushion sensitive areas on the body, to provide more
comfort, to support mild deformations, or
for small, lightweight clients.
The Medium formula is suitable for the
average-size adult and for body weights
up to and including 300 lb. It yields less
than the Soft formulation under pressure,
providing more support, yet still allows for
gentle immersion into the cushion.
Density 5.2 lb/ft3
Density 5.2 lb/ft3
Open Mold Expansion Factor* 7-8 times
liquid volume
Open Mold Expansion Factor* 7-8 times
liquid volume
Support Medium pressure support
Support Low pressure, contour adaptation
Semi-rigid is rarely used for wheelchair
seating, but may be used to create a
firm, lightweight base support, or to pour
custom molds for use in extreme environments such as race car or aircraft seating.
Choose Semi-rigid when portability is a
factor, when carrying weight must be minimal, or when impact protection or vibration
absorption is beneficial.
This low-density foam is about 40%
lighter than Medium, and expands to 30%
more volume than Medium and 55% more
volume than Soft.
Density 4.3 lb/ft3
*Expansion Factor: comparison of the reacted SunMate® volume to the Liquid SunMate® volume.
Bag Pack,
Open
34% Mold Expansion Factor* 9 times
11/2 un
16%
liquid volume
Extra-soft, Medium-soft, and Medium-firm are available upon request.
Bowl Pack,
Support Extra-firm
support, lightweight
66%
How to Choose Support Pressure
Select cushion support pressure based on the weight and build of the client, the degree of immersion required depending on the
Bowl vs. Bag
client’s sensitivity to pressure, the client’s comfort preferences or support needs, and specific application
requirements. These charts
Customer Preference
show general recommendations and order trends of other seating specialists.
Med-firm, .6%
XSo
Me So ft
f
M d-S t
ed of
iu t
m
Build
XXXL
XXL
XL
L
M
S
XS
M
ed
i
-F
Fi
F
X-
Semi-rigid, .4%
Extra
soft
6%
Medium
25%
rm
rm
Unit S
irm
Med-soft
2%
Soft, 66%
Support Pressure Order Trend
40 80 120 160200240280
Weight (lb)
As shown in this chart, the Extra-soft formula
would provide the necessary support and comfort
for a 90-lb person with a small frame.
Private Agency: 4%
Therapist, Individual, Prothetics: 8%
Race Car, Motorcycle,
Specialty, Veterinary: 10%
Liquid SunMate® FIPS Instruction Manual 5
A
Safety and Handling
The chemicals used in Liquid SunMate® FIPS were selected due to their mild nature and minimal
toxicity. These chemicals are safe to work with when proper precautions are taken. For complete
details, read the Safety Data Sheets included with each unit.
Precautions
• Keep containers tightly sealed until ready to use.
• Do not leave containers where the curious may handle.
• Wear protective clothing, gloves and safety glasses.
• Cover mixing area, floor and chair with drop cloths.
• Work in a well-ventilated area.
• People with certain allergies may be sensitive to FIPS.
• If containers feel cold, or the Iso appears cloudy or crystallized, follow
the Cold Weather Heating Instructions before use.
Chemical Ingredients
Polyol
Polyol determines the support pressure
of the cushion. It consists of many
different ingredients, 32-42% of which
are plant-based. Some Polyol ingredients
will settle over time, so it must be wellmixed before using to ensure the highest
quality foam rise. Polyol is relatively inert
and is not considered hazardous or
toxic, but people with sensitive skin may
experience mild skin irritation on contact.
Each batch of Polyol is quality tested before packaging. The lot
number can be found on the outside of the packing box and on
the Polyol container. (See Appendix B, pg. 18.)
Catalyst
The Catalyst must be mixed with the Polyol or the foaming action will not occur. The amount of Catalyst used
determines the speed and temperature of the reaction.
The Catalyst is a skin and eye irritant. Take care not to
get it on a gloved hand and accidentally transfer it to the
eyes or an unprotected area of skin.
Iso
Iso is the reactive ingredient that produces
carbon dioxide gas when added to the PolyolCatalyst mixture. Iso, the mildest form of
isocyanate (methylenediphenyl diisocyanate, or
MDI), provides the chemical linkage necessary
to generate an elastic foam. It does not release
any volatile fumes at room temperature, however,
if temperatures exceed 150°f, it can produce
fumes. Persistent inhalation of fumes at high
temperatures could cause temporary, asthmaticlike breathing difficulty. (See Appendix C, pg. 19.)
If skin comes into contact with the Iso, wash
the exposed area as soon as possible, otherwise
the Iso will react slowly with proteins and moisture in the skin and
cause a layer of dead, dry skin to form over a few days. The dried
skin will eventually slough off and be replaced by new skin.
Chemical Combination
Polyol, Catalyst and Iso, when combined, react and generate
heat and slight fumes. The fumes are well within OSHA standards
for safe exposure limits and are generally not noticeable or
problematic.
No adverse effects will result from using this system unless
exposed to chemicals in quantities significantly greater than the
contents of the FIPS package, or excessively exposed by not
following safe handling procedures.
6 Liquid SunMate® FIPS Instruction Manual
Spill Protection and Prevention
•Both the person mixing and the person being molded should
remove all jewelry, secure long hair, and wear old or disposable
clothing.
•The person being molded should wear sufficient hair protection
such as a shower cap.
•The person mixing should wear gloves and safety glasses.
•Cover the floor, wheelchair, and mixing area with drop cloths.
•Inspect the molding bag for holes or tears before the pour.
•Maintain a safe distance from others when mixing the chemicals.
•Bowl PACK TIP: Place the mixing bowl inside a cardboard box
when mixing the ingredients to contain beater splashes or spills.
•BAG PACK: Firmly grasp the Bag Lock when shaking the foil
bag to prevent premature opening.
•If a hole appears in the molding bag after pouring the liquid
mixture, pinch the bag closed (using gloved fingers) until the
foaming reaction stops.
•Place a large trash can nearby to dispose of the foil bag or mixing bowl after the mixture is poured, to catch any foam overflow,
or to abandon a pour and throw away the mix in an emergency.
In Case of Spills
Skin or Eye Contact
If any of the chemicals come into contact with the skin, immediately
wash affected areas with soap and water. Repeat 2-3 times.
If any of the chemicals are transferred to the eye(s), immediately
flush with tepid water for 15 minutes at a sink or eye wash station.
Spill and Leak Cleanup
Use an absorbent material such as cat litter or sand to clean up
individual chemical spills. Neutralize the area with a mild ammonia
solution. Dispose of the trash as a solid waste and clean the area with
soap and water.
If a spill occurs after the three chemicals have been mixed together,
they will react, foam, and adhere tenaciously to any surface onto which
the mixture has spilled. The following treatments are recommended:
Foam on Clothing, Fabric or Carpet: If possible, remove the foam
while it is still tacky, before it sets. Do not smear it. Use gloved fingers
to carefully remove the foam from the affected surface. Due to the
liquid foam’s adhesive nature, any remaining residue becomes permanently embedded in the fibers.
Foam on Skin: Liquid foam spills to the skin are not toxic but may
cause mild skin irritation until the foam residue peels off after a day or
two. The body’s natural oils will loosen the foam. Apply baby oil or lotion to soften the affected area.
Foam in Hair: Carefully separate the affected hair from unaffected hair
with gloved fingers. Dab the liquid foam with an absorbent cloth. Do not
smear it. Once the liquid becomes a solid foam, the only recourse is to
cut it out of the hair.
Foam on Smooth, Hard Surfaces: Let the foam cure and carefully
remove it with a putty knife.
Before You Pour
Prior to the molding day, check the shelf life of each Liquid SunMate® FIPS unit. Make sure it does not
exceed the 9-month range recommended for good foam quality. If the Bag Pack Iso or Polyol sections
feel thick and cold, or the Bowl Pack Iso appears cloudy or crystallized, follow the cold weather heating
instructions. For the best, safest reaction, the chemicals MUST be at room temperature before using.
Adequate Work Space
Work in a well-organized, ventilated area spacious enough for the
client, the wheelchair, and the seating team. Access to an electrical outlet may be necessary for using mixing or trimming tools.
Collect all the necessary materials before beginning.
Schedule Enough Time
The mixing and pouring stage only takes about 10 minutes, however, the complete process, including setup, can take up to an
hour. Finishing steps can take up to 2-4 more hours depending on
fabric choice, waterproofing method, size and complexity of the
mold. Finishing may be postponed to another day if the need for
the cushion is not urgent.
Prepare the Chair
Chair Fit
It is important for the cushion to be molded in the client’s own
chair. There should be enough space between the client and the
frame of the chair to allow for foam expansion.
Select the Proper Base
Molding on or against a firm, flat surface provides the best pressure control. If the chair has a “sling” seat or back, insert a more
stable plywood or plastic base, or make a solid chair frame.
Additional Supports
Plywood, plastic or cardboard inserts can be used to direct the
foam expansion and guide the liquid into areas where it needs to
flow to accommodate positioning. Modifications such as lateral
supports, abductors, adductors, or foot supports may be used to
help shape the mold.
Drop Cloths
Err on the side of caution to protect valuable equipment, furniture
and flooring. Place drop cloths over the mixing area, chair, and
floor in case of accidental spills. Liquid foam adheres tenaciously
to most surfaces once it cures.
Material Checklist Safety
Disposable gloves and safety glasses (for person handling chemicals)
Shower cap (to cover client’s hair)
Protective clothing or towels (for client and person mixing)
Drop cloths (to cover mixing area, floor and chair)
Large trash can
Paper towels and absorbent materials (in case of spills)
Molding Bag Preparation
Heavy duty, light colored, 33-gallon plastic garbage bag(s), at least 1.4 mil
Permanent ink marker and yard stick (for marking centerline)
SunMate® base cushion(s), 16" x 18" x 1"
Mixing the Chemicals
Electric mixer (Bowl Pack only)
Chair Prep
Optional supports or extensions (to direct foam expansion)
Trimming
Permanent ink marker (to mark areas to be trimmed)
Electric knife, box cutting knife and/or die grinder
Laminate and Fabric cover
⁄4" thick SunMate® sheet (size depends on size of insert)
3m™ Foam Fast 74 spray adhesive
2-way or 4-way stretch fabric (1-2 yd)
Scissors (for trimming excess material)
Tongue stick (for gluing seams)
1
Waterproofing
Dow Corning® RTV 732 multi-purpose sealant (quantity depends on size
of insert)
Caulking gun and spreader(s)
Disposable gloves
Paper towels
Masking tape (for creating neat edges)
Tongue stick and dye (if you prefer a color other than white)

cardboard to direct
upward foam flow
A temporary or permanent frame may be constructed to provide a sturdy base for
the mold.
Cardboard may be affixed to the chair to direct the flow of liquid
foam up and around the body.
Liquid SunMate® FIPS Instruction Manual 7
Protect and Prepare the Client
Internal temperature of the reacting foam can reach 140ºf. The
client’s skin must be protected from the heat generated by the rising foam. An additional layer of clothing or a towel placed between
the molding bag and client’s body should provide a sufficient barrier. Explain to the client what to expect in terms of the sensation
of heat and foam expansion generated by the reaction. For most,
it is a very soothing experience, like sitting in a warm bath.
Long hair should be secured and covered with a shower cap or
hat to protect it from accidental spills.
When pouring a Liquid SunMate® FIPS mold for a young child,
elderly or disabled person, a therapist or seating specialist should
be on-hand to assist the client, if necessary, to help hold the body
in position while the foam is rising. This ensures that the liquid
can flow where it needs to to allow for correct alignment, support,
comfort, and increased body function.
Prepare the Team
A trial run-through before the actual pour is good practice for
the team, and the client if possible, to become familiar with the
process and timing of events.
Assign responsibilities to each person. Decide who will:
•Adjust the chair frame or supports
•Prep the molding bag and hold it open for the pour
•Mix the liquids and pour them into the molding bag
•Transfer the client to and from the chair
•Position the client
•Monitor the foam rise
Take simple safety precautions. Wear protective layers of clothing, disposable gloves, safety glasses, and hair protection. Use drop cloths to protect
the chair and floor.
Trial Positioning
One way to ensure a successful pour is to allow ample time for a
seating assessment with the client to determine the goals to be
achieved with the cushion mold. Familiarize the team with their
responsibilities and let the client know what to expect during the
molding session.
•Check the height of the molding bag while the client is seated.
It should be high enough to contain the rise and allow for clearance should the foam rise high enough to flow out of the bag
opening.
•The chair should be large enough to allow the liquid to flow
around the client as needed. Always have a trash can positioned behind or near the chair to catch any overflow.
•Using a seat belt or harness to hold the client in the chair is not
recommended as it will restrict the flow of the foam.
After trial-positioning, remove the client from the chair and prepare the molding bag for the pour. Center the molding bag in the
chair and open the top of the bag so the mixture can be poured
quickly and easily.
8 Liquid SunMate® FIPS Instruction Manual
Assess the fit of the chair before the pour. There should be room to
accommodate the molded insert. Make sure the molding bag height is
sufficient to contain the rising foam and prevent overflow.
Prepare the Molding Bag
Use a tough (1.4 mil), plastic, polyethylene bag with a squaredoff bottom for molding. Light-colored or transparent bags allow
viewing of the foam rise. A 33-gallon bag is sufficient for molding
a seat or back cushion for an adult. A 13-gallon bag works well
for molding a seat or back cushion for a child or small-framed
adult.
Only one molding bag is needed when making a seat or a
back cushion, with the following exceptions:
A. Molding Large Adults A tall or heavy person may require two bags taped together or a
single, large bag. If using two bags, cut open the bottom of one
bag and seal it well to the opening of the second bag with 2"
packing tape. (Most medical tapes are unsuitable because the
heat of the reaction softens the adhesive.)
B. Using the Semi-rigid Formulation The Semi-rigid formulation expands 35-50% more in volume than
the Soft or Medium formulation. Two bags taped together or one
large bag may be required to allow for excess expansion.
Step 1 Draw a centerline on the molding bag.
A
B
For a Back or a Seat Cushion
Step 1: Place the molding bag on a table and draw a centerline
down the middle with a felt marker. Use this guide to center the
base cushion(s) in the bag and the bag in the chair.
Step 2: When molding a Back cushion, place one 16" x 18" x 1"
SunMate® base cushion inside the molding bag. (See figure 2A.)
When molding a Seat cushion, insert a second 16" x 18" x 1" base
cushion into the molding bag (as shown in figure 2B). The base
cushion(s) provides an underlying support surface onto which
the liquid foam will adhere.
Step 2 A) When molding a Back cushion, insert one base cushion.
B) When molding a Seat cushion, insert two base cushions.
Step 3: Place the molding bag in the chair so that the base
cushion(s) rests on the seat and/or against the back of the chair.
For a Total Insert
You will need two separate molding bags to mold a total insert:
one for the seat and one for the back. A total insert requires three
16" x 18" x 1" base cushions. Prepare each molding bag using
the steps listed above.
TIP
Trash compactor bags are a perfect size for molding inside a fabric-finished back bag for a child or small-framed person. The bags also peel
away from the cured foam insert more easily than most garbage bags.
IMPORTANT
Never leave the molding bag on the foam insert. It must be removed
shortly after the foam cures or else it will cause the cushion to
become firm.
Step 3 Place the molding bag in the chair. This one has been prepared for
molding a seat cushion.
Liquid SunMate® FIPS Instruction Manual 9
Molding a Custom Seat Cushion with the FIPS Bag Pack
The Liquid SunMate® FIPS Bag Pack ingredients are contained in 3 sections of the foil bag separated by
plastic clips. They are mixed by removing the clips in order and manually kneading and shaking the bag.
Catalyst
Polyol
Iso
One Full Bag unit includes:
•
•
•
•
Inspect the Bag for Leaks
The day before the pour, inspect the Bag Pack carefully for leaks. If the Polyol or Iso sections feel
cold or lumpy, follow the Cold Weather Heating Instructions in Appendix D, pg. 20.
Polyol, 3 lb section
Catalyst, 1 oz section*
Iso, 1½ lb section*
FIPS Summary Guide (includes Safety
Data Sheets and Cold Weather Heating
Instructions)
*Catalyst and Iso amounts vary by formulation.
Bag Lock

Clip 1 
trash




Mix polyol for 2 minutes
Using kneading and shaking action, mix
the Polyol section for at least 2 minutes to ensure any ingredients that have settled in storage
are well-mixed into a uniform consistency.
remove clip 1 to add catalyst
Remove Clip 1 between the Catalyst and
Polyol by removing the red end cap and pulling
the white rubber tubing out of the c-clip.

Place Molding Bag in chair
Place the base cushion(s) inside the
molding bag and position the molding bag in the
chair. Have a trash can nearby.

Pour mix into Molding Bag
Lower the Bag Pack into the molding bag
and pour the mixture onto the base cushion
toward the front of the chair using a side-to-side
motion. Squeeze any excess out of the bag and
throw the empty Bag Pack into the trash can.
10 Spread Mixture Evenly
Working from the outside of the molding
bag, quickly spread the liquid evenly across
the seat. You can only manipulate the mixture
while it is in liquid form. Once the foaming action
begins, additional handling or movement causes
the bubbles to break, and creates hard spots in
the finished cushion.
Liquid SunMate® FIPS Instruction Manual
seat Client
Quickly and carefully transfer the client
onto the molding bag. CAUTION: Make sure the
client’s clothing does not shift to expose the skin
during positioning.
The client must remain as still as possible for
at least 5 minutes while the foam rises. Make
sure nothing is restricting the flow of the foam so
it can rise and fill any voids.
Place a trash can under the bag opening to
capture any overflow, and stand away from the
bag opening to avoid breathing any escaping
gases.
SAFETY TIPS
Temperatures
Below 50°F
Crystallize Iso
Heat Carefully
per Instructions
IMPORTANT
Work in a well-ventilated area and protect the
chair and floor with drop cloths.
Always hold the bag by the plastic clips when
shaking to ensure the clips stay in place.
Stand over a drop cloth and shake the bag a
safe distance away from others to avoid
accidental spills.
SHELF LIFE
The Liquid SunMate FIPS Bag Pack has a
shelf-life of 9 months from the purchase date.
Each box is labelled with a sticker indicating
the latest date by which the chemicals must
be used.
®
When molding a seat insert, the client can
easily slide out of position before foaming
starts. Gently hold the client in position by the
knees or pelvis. If a larger abductor is needed,
hold the knees apart slightly during the rise.
Do not wait until the foam starts rising to seat
the client on the molding bag. This will cause
the small bubbles to break and will create hard
spots in the finished cushion.
Shipping and Storage
The U.S. Department of Transportation does not require the FIPS chemicals to carry a “hazardous”
label when shipped. They may be safely handled, shipped, and stored using normal care.
The FIPS chemicals should be stored at room temperature (60-75ºf). They are not volatile or
readily flammable, however, they will react slowly with moisture. All containers should be sealed
tightly until ready for use.
clip 2

Hold ends of bag securely
Polyol-Catalyst
mixture
 

Iso


mix catalyst for 30 seconds
Knead, shake and slosh the bag until the
Polyol and Catalyst are uniformly mixed (about
30 seconds).
The Catalyst controls the temperature and
speed of the reaction. No reaction will take place
until the Iso is added in the next step. The process may be halted at this stage if necessary.

REMOVE CLIP 2 to add iso
Remove Clip 2 between the Polyol-Catalyst mixture and the Iso. Be prepared to move
quickly.
STOP! Make sure everyone is ready
before proceeding.

Shake Bag for 15 seconds
Holding the ends of the bag securely, vigorously shake the bag from side to side and up
and down for 15 seconds until it begins to feel
warm. Slight warmth indicates that the foaming
process is about to start.
Remove the Bag Lock before pressure builds
up in the bag and grip the bag opening, holding
it closed as you move toward the molding bag
to pour.
trim line


Release trapped air
Just before the foam starts to set, release
trapped air in the molding bag by poking small
holes in the front corners of the bag or in the
pommel area between the legs. Protect the client
from any liquid that may escape through the hole.
The cured foam Seat CUSHION
Once the foam has cured, peel the molding bag
from the foam. Mark and trim away any excess
cushion material. Laminate, fabric finish and
waterproof as needed.
A Complete Rise
After about 10 minutes, the foaming process
is complete and the cushion is ready to be
trimmed and finished.
Liquid SunMate® FIPS Instruction Manual 11
Molding a Custom Back Cushion with the FIPS Bowl Pack
The Liquid SunMate® Bowl Pack ingredients are packaged in 3 separate containers. They are combined in
a bowl (included) in a specific order and mixed with electric beaters.
SHELF LIFE
The Liquid SunMate® FIPS Bowl Pack has a shelf-life of 9 months from the purchase date. Each
box is labelled with a sticker indicating the latest date by which the chemicals must be used.
One Full BOWL unit includes:
•
•
•
•
•
•
Polyol, 3 lb container
Catalyst, 1 oz bottle*
Iso, 1½ lb container*
Mixing Bowl
Mixing Stick
FIPS Summary Guide (includes Safety
Data Sheets and Cold Weather Heating
Instructions)
*Catalyst and Iso amounts vary by formulation.

add iso. MIX for 15 seconds.
Place the mixer in the bowl. Turn it on
high speed and quickly pour the Iso without
splashing it onto the beaters. Mix for 15 seconds. The mixture should have a thin, aqueous
consistency. Lift the mixer slightly above the
liquid and briefly spin the beaters clean. Set the
mixer aside.




Inspect Containers
The day before the pour, unpack the
chemicals and inspect them carefully. If the
Polyol is cold and thick or the Iso is cloudy or
crystallized, follow the Cold Weather Heating
Instructions in Appendix D, pg. 20.
Pour mix into Molding Bag
Have the client lean forward, and lower
the bowl into the molding bag. Pour the mixture
quickly and evenly into the bottom of the bag.
Set the bowl aside and have the client lean back
into position. Adjust the molding bag to ensure it
is not restricting the flow of the liquid foam.
Place Molding Bag in chair
Place the base cushion inside the molding
bag and position the molding bag in the chair.
Place a trash can behind the chair, and seat the
client.
(When making a Total insert, place the molding
bag on top of the previously molded seat cushion, as shown in the above photo.)
lean client back
While the reaction is occurring, stand
away from the bag opening to avoid breathing
any escaping gases. Do not poke the foam as
it rises as it will cause the tiny bubbles to break
creating hard spots in the cushion.
Place a trash can beneath the opening of the
bag to catch any overflow.
Shipping and Storage
The U.S. Department of Transportation does not require the FIPS chemicals to carry a “hazardous” label when shipped. They may be safely handled,
shipped, and stored using normal care.
The FIPS chemicals should be stored at room temperature (60-75ºf). They are not volatile or readily flammable, however, they will react slowly with
moisture. All containers should be sealed tightly until ready for use.
12 Liquid SunMate® FIPS Instruction Manual
SAFETY TIPS
IMPORTANT
Work in a well-ventilated area and protect the
chair and floor with drop cloths.
Chemicals must be mixed in the order specified.
To minimize the risk of spills or splashes, place
the mixing bowl inside the packing box to mix.

pour polyol into mixing bowl
With the Polyol at room temperature, pour
it into the three-quart mixing bowl. Use the mixing
stick to scrape all remaining sediment into the
bowl. The older the unit, the thicker the Polyol
will be.
Temperatures
Below 50°F
Crystallize Iso
Heat Carefully
per Instructions
Do not push on the molding bag while the
foam is rising. This will cause the small
bubbles to break and will create hard spots in
the finished cushion.

Mix polyol for 2 minutes
Mix the Polyol on high speed for 2 minutes to obtain uniform consistency. Thorough
mixing is key to creating a cushion with good
cell structure and support properties.

add catalyst. mix for 30 seconds.
Add the Catalyst and mix for 30 seconds.
The Catalyst controls the speed and heat of
the reaction. The process may be halted at this
stage if necessary. No reaction will take place
until the Iso is added.
The foaming reaction occurs very quickly
once the Iso is added to the mix.
STOP! Make sure everyone is ready
before proceeding.

trim line

monitor foam rise
Hold the client’s shoulders or chest in
position as the rising foam may push the client
forward. The client must remain seated, as still
as possible, for at least 5 minutes while the
liquid rises and cures.

A Complete Rise
After about 10 minutes, the foaming process is complete and the back cushion is ready
to be trimmed and finished.
TRIM EXCESS FOAM
Once the foam has cured, peel the molding bag
from the foam. Mark and trim away any excess
cushion material. Laminate, fabric finish and
waterproof as needed.
Bowl Pack Waste Disposal
To minimize the risk of spills, always replace the lids on the containers after the chemicals have been used. To clean up, pour any Catalyst residue
into the Iso bottle. Add a small amount of water and mix gently. Loosely recap the Iso bottle to allow resulting gases to escape. Once the chemicals
react, they become a solid waste which may be disposed of in the trash. Do not pour Iso down the drain. It reacts with water and will produce hard
crystals that will clog the drain.
Liquid SunMate® FIPS Instruction Manual 13
Finishing the Cushion
Once the foam has cured, the cushion is ready for finishing. First, trim away any excess material. Then,
adhere a ¼" layer of Soft SunMate® to the surface. Finally, cover the cushion with either a “hairnet”,
stretch-knit, or waterproof fabric. Waterproof coating application (shown on pg. 16) is optional depending on the fabric used and level of protection required.
Trimming

About 15 minutes after the pour, the foam
will have finished curing and may be
trimmed. Cut away all excess foam that will not
provide any positioning, comfort or support need.

Remove the plastic molding bag. It CANNOT be used as a waterproof barrier
and will cause the cushion to harden if it is not
removed.

For total inserts, mark the seat and
back cushions so they can be re-aligned
after they are removed from the chair.
TRIMMING TIP
Cut outs can be made beneath high pressure points or areas where tender skin is susceptible to
heat or friction. Place a Pudgee™, gel, or air cell insert into the void to reduce pressure, shearing,
or temperature. Ventilation holes or slits for harnesses or belts can be added before laminating.
Cut too much away? Simply glue it back!
Laminating
Before laminating, you must trim a ¼" layer
away from the interior surface of the cushion maintaining the contour of the mold.
This material will be replaced by gluing
a ¼" thick sheet of Soft SunMate® to the
surface to create a smooth, comfortable,
aesthetically pleasing finish.




Lay the ¼" laminate over the cushion and
fold it back over itself. Using a permanent
foam adhesive, spray half of the seating surface
and half of the ¼" laminate. Wait a minute for
the glue to become tacky.
Fabric Covering
Simple solutions to fabric covering are to
mold directly into a fabric-finished molding
bag, or to use a simple elastic “hairnet”
cover. Otherwise, a 4-way stretch fabric
may be glued to the surface to increase
the protection, durability, and life of the
cushion. Choosing
a waterproof fabric
eliminates the need
to apply a waterproof coating, and
makes the insert
easy to clean or
sterilize.
Easy “hairnet” cover
14 Lay the fabric over the cushion and fold it
back over itself. Spray half of the cushion
with foam adhesive, and wait for it to become
tacky. Break the bubbles and spread the glue
evenly using a tongue stick. DO NOT SPRAY
THE FABRIC.
Liquid SunMate® FIPS Instruction Manual
Press the two surfaces together, gently
pulling and smoothing the laminate until
an even contact is made.
Repeat this process until the laminate is
adhered to the remainder of the seating surface.
Prevent air pockets from forming by pressing
the laminate for a few minutes until the contact
holds. This is particularly necessary in deep
recesses.
Starting in the deepest recess, press the
fabric into place. Gently pull and stretch the
fabric around the sides being careful not to pull
the contour of the cushion out of shape. Repeat
the process to adhere the fabric to the rest of the
cushion.
Trimming Items Needed
Lamination Items Needed
•
•
•
•
• 16" x 37" x ¼" (or larger) SunMate sheet
• 3M FoamFast 74™ spray contact adhesive
• Scissors
Felt-tip marker
Electric knife
Paring knife or box cutter (optional)
Die grinder (optional)
Fabric Covering Items Needed
®
• 4-way stretch fabric (1 yd for seat or back,
2 or more yards for a total insert)
• 3M FoamFast 74™ spray contact adhesive
• Scissors
alignment
guidelines









Glue the back and seat cushions together
before surface-finishing with the laminate
and fabric cover.
At the corners of the insert, pinch the
excess laminate together and trim it about
a ¼" from the edge of the cushion.
Avoid creating any seams or wrinkles
on the seating surface. Seams may be
placed on the back, bottom or sides of the
insert. To make a seam, pinch the excess fabric
together to make a dart, and trim the fabric ¼"
from the cushion edge.
Reseat the client on the new cushion. Assess the fit and mark any areas that need
additional trimming.
Use an electric knife to trim away any surface
irregularities that might cause skin irritation
or pressure points. A die grinder is useful for
smoothing irregularities in deep contours of the
insert.
Apply adhesive to the cut edges and pinch
them together to make a seam.
Use a tongue stick to push one side of the
fabric underneath the other, adding glue to
the seam to hold it together if necessary.

Trim around the thigh depressions to
allow room for air circulation and movement. Bevel any rough edges.
After the initial trim, temporarily cover the
insert so the client may try it for a few days.
Observe the client’s fit and function during that
time and make further adjustments as necessary. Once trimming is complete, the insert may
be laminated.
Finish all seams before moving on to the
fabric finishing stage.
Accidental glue sprays on the top surface
of the fabric may be removed with masking tape before the glue dries.
Liquid SunMate® FIPS Instruction Manual 15
Waterproofing
Applying a silicone elastomer coating to your FIPS cushion creates a
flexible waterproof seal that stretches with the foam as it compresses,
and will not detract from the cushion's support properties. The surface
is easily cleaned with soap and water and may be sterilized with steam
or antibacterial disinfectant. Silicone may be applied directly to foam or to
cotton-knit fabric, and is safe for skin contact.
Applying a Silicone Coating
MAterIAls neeDeD
• 2-4 tubes of dow Corning® 732 RtV
multi-purpose sealant
• Plastic spreader
• disposable gloves
• Plastic drop cloths
• Masking tape
Work in a well-ventilated area. The 732 RTV silicone has a highly acidic, vinegar smell.
Once the silicone dries, the odor disappears. If you do not smell this strong odor when
you begin to use the product, it may be beyond its shelf-life and may not dry properly.
Always check the use-by date before buying or applying the sealant.
Wear disposable gloves and cover the work area with plastic drop cloths. Make sure
the surface area being waterproofed is dry and oil-free.
The following steps describe waterproofing all sides of a seat or back cushion. Waterproofing only the seat cavity (as shown in the photos), requires only 1 tube of silicone.
IMPortAnt
do Not CoMBiNe different brands of
silicone on the same cushion as they may not
be compatible.
The silicone coating will add slight firmness
to your cushion. to combat this effect, if you
know you will be applying the waterproof
coating, order a formulation one-degree softer than necessary for support. For example, a
waterproofed extra-soft FiPS cushion will feel
and perform like a Soft.
Free samples of each formulation as cured
foam are available upon request.

Apply the silicone evenly, holding the
spreader vertically for good penetration.
Coat the top and sides of the insert and let it dry
for 1 hour.
When waterproofing just the seat cavity, outline
the area to be treated with masking tape for neat
edges. Remove the tape before the silicone
dries completely.

to apply the second coat, empty the
remainder of the tube contents onto the
seating surface.

to start, empty ½ of the tube onto the
cushion surface. You may add more as
you go if necessary.

Apply the second coat holding the
spreader at a 45º angle. this coat should
be thin and smooth.
tIP
if the waterproof coating generates uncomfortable heat buildup for the client, a thin towel
may be placed between the body and the
cushion to reduce perspiration.

to eliminate ridges, before the silicone
dries, gently rub a mixture of warm water
and dish detergent into the second coat using
your fingertips.
16

When waterproofing the entire cushion,
finish one side allowing the coating to
dry completely, then turn the cushion over and
repeat steps 1-5.
LiqUid SUNMAte® FiPS iNStRUCtioN MANUAL
Appendix A
Custom Sizes
Making Larger and Smaller Molds
One advantage of using the Bowl Pack is that the containers can be
opened individually and the chemicals utilized in smaller quantities.
All chemicals must be proportioned by weight, not by volume. When
preparing your own fractional mixture, refer to the table below. To proportion the ingredients, first weigh the desired quantity of Polyol. Then
determine the amounts of Catalyst and Iso needed by multiplying the
Polyol weight by the appropriate percentages listed.
Bulk chemicals are available upon request. Call for pricing.
Calculating Proportions of Liquid SunMate® FIPS for Custom Sizes
SOFT
weight%
for one unit
weight
for one unit
%
SEMI-RIGIDweight
for one unit
%
100
MEDIUM Polyol
Polyol
1420 g
1360 g
100
Polyol
100
Catalyst 20 g
1.5
Catalyst
20 g
1.5
Catalyst
Iso 612 g 43
Iso
Total Wt.
Total Wt.
2052 g
680 g 50
Iso
Total Wt.
2060 g
1280 g
12 g 1
756 g 59
2048 g
All weights are approximate. The exact amount varies somewhat with Soft, Medium and Semi-Rigid formulations as shown in the table.
Fire Safety Options
FRG Fire Retardant Additive for Liquid SunMate® FIPS Bowl Pack
A cushion made with Liquid SunMate® FIPS will pass the CAL 117 Section D, Part II burn test without the use of any fire-retardant
additive, coating, or FR fabric cover. However, Dynamic Systems offers a non-halogenated fire retardant additive that can be used
with the Liquid SunMate® FIPS Bowl Pack to allow the cushion to pass the British Standard 5852 Part 2/1324 Source #5 (Crib 5) and
the FAA 12-second vertical burn test, Vert FAR 25.853(a). The optional fire-retardant additive, called FRG, comes packaged with the
FIPS unit in a separate container, and is added to the Polyol during the mixing process. An additional charge applies.
How to Dispose of Expired Chemicals
A “Use By” date is printed on each box of Liquid SunMate® FIPS. If the product has passed this date before you are able to use it,
you have the following options:
1.Order replacement Iso (Bowl Pack only). The product will still be usable with new Iso.
2.Return unused chemicals to Dynamic Systems for disposal. Shipping charges apply.
3.Use the following method to dispose of the chemicals. (Comply with any local, state, and
federal laws and regulations which may be more stringent.)
Always wear disposable gloves and eye protection when disposing of the chemicals.
Bowl Packaging Disposal Method
To dispose of the Iso and Catalyst:
• Pour an absorbent material such as cat litter or sand into the
bottom of two double-bagged trash bags.
• Pour the contents of the Iso bottle into the trash bag.
• Pour the contents of the Catalyst bottle into the trash bag.
Avoid breathing any resulting outgassing fumes.
• The trash bag and empty bottles may then be disposed of as
household trash. Polyol, which is derived primarily from plants,
may be thrown away as originally packaged in the container.
Bag Packaging Disposal Method
To dispose of the Iso and Catalyst:
• Pour an absorbent material such as cat litter or sand into the
bottom of two double-bagged trash bags.
• Carefully cut open the end of the Iso section of the foil Bag
Pack and pour the contents into the trash bag.
• Carefully cut open the Catalyst section and pour the contents
into the trash bag. Avoid breathing any resulting outgassing
fumes.
• The trash bag and remainder of the foil FIPS Bag Pack (containing only Polyol) may then be disposed of as household trash.
Liquid SunMate® FIPS Instruction Manual 17
Appendix B – Reading Labels
Read all labels carefully before using the chemicals. They contain important safety and handling information.
Support Pressure Labels
FIPS formulations are color-coded for easy identification.
soft
soft Polyol is pink, and the chemical containers and packing boxes are all marked with
small round red stickers.
Medium Polyol is blue, and
the chemical containers and packing boxes
are all marked with small round blue stickers.
Medium
semi-rigid Polyol is white
semi-rigid or light green, and the chemical containers
and packing boxes are all marked with small
round green stickers.
Polyol may be requested without dye to make a white cushion.
Important Safety and Handling Labels
For complete safety and handling information about each chemical, read the Safety Data Sheets enclosed with each FIPS unit.
Important Dates on the FIPS Packing Box
Before using the product, check the expiration date. Both the
Bowl and Bag Packs have a shelf life of 9 months from date
of manufacture. Every unit is stamped with a use By date and
a lot# record of the date and time a specific batch was made
and packaged for delivery.
How to Read a Lot#
For example, in the above photo, the Lot# 140402-0830, reading from left to right, “14” is the year 2014, “04” is the month of
April, “02” is the day the unit was packaged, and “0830” is the
time the batch was made (8:30 a.m.).
18
LiqUid SUNMAte® FiPS iNStRUCtioN MANUAL
Appendix C – Iso Safety
MDI Information
Please read the sidebar information carefully. It contains a summary of the 1990 MDI Toxicity Report by CIVO and additional
in-house research data.
The most essential safety factor is for all users of the Liquid
SunMate® FIPS system to have a clear understanding of the
proper handling procedures and use of this chemical.
Iso Safety Levels
The Occupational Safety and Health Administration (OSHA)
has set safe isocyanate exposure limits, which are based on
extensive studies and are set as low as is necessary to avoid all
ill effects. According to OSHA guidelines, the concentration of
isocyanate should not exceed 0.02 ppm (parts per million) in the
work space. Research test results printed in the references cited
below indicate that Iso fumes from normal Liquid SunMate® FIPS
usage do not exceed the OSHA exposure limits.
1. The Journal of Occupational Medicine (April 1969, vol. ii, no. 4)
cites research in which a 10-minute mixing and pouring of an
MDI system (similar to the Iso system), performed in a sealed
room, produced isocyanate levels of only 0.004 ppm. This is only
1/5 of the OSHA limit.
2. Technical Bulletin 107 (Upjohn Co., 1980) indicated that a freestanding, open container of Iso will not produce fumes near its
opening in excess of OSHA standards until the temperature
reaches 100ºf.
3.The International Isocyanate Institute, Inc. initiated a two-year
study of polymeric methylenediphenyl diisocyanate (MDI) at
CIVO Institutes, Zeist, The Netherlands, in June 1985. Preliminary results from this study are available and are briefly
described in the following paragraphs.
Due to its physical characteristics, it was not possible to generate a
vapor atmosphere of MDI high enough to carry out a meaningful study.
Therefore, an aerosol was used to expose rats six hours per day, five
days per week for two years to an atmosphere of MDI. Concentrations
used were: 0, 0.2, 1.0 and 6.0 mg/m3. The current TLV for MDI is 0.005
ppm or 0.055 mg/m3.
The overall tumor incidence did not show statistically significant
differences between the high exposure group and the control group.
We do not believe these results require a change in our view of risk
to people from exposure to MDI at otherwise acceptable levels. The
currently suggested control levels, either the TLV of 0.005 ppm as a
TWA or the OSHA PEL of 0.02 ppm ceiling (0.2 mg/m3), which are set
to protect against a variety of other effects on the respiratory system,
are well below levels that cause irritation to the respiratory tract.
summary of MDI toxicity
• It is not possible to generate sufficient concentrations of
MDI (Iso) vapor at room temperatures to produce unsafe
MDI levels.
• CIVO had to use an MDI aerosol spray in order to reach
unsafe MDI levels. An aerosol is not generated in the Liquid
SunMate® FIPS process.
• The levels of fumes produced in the Liquid SunMate® FIPS
process are well below the OSHA allowances, and well below the levels tested by CIVO wherein no toxic effects were
detected.
• MDI produces minimal toxic fumes during the foaming
process. In keeping with safe handling practices, however,
we stress the need for good ventilation. Stand away from the
bag opening, and keep the bag opening folded downwards
to reduce fume escape.
• MDI fumes are not generated until the mixture starts to warm
and produce gases during the foaming process. By this
time, the mix is inside the molding bag and the bag opening
may be totally restricted using the following method:
If the potential for fume generation concerns safety personnel, a simple filter can be made by removing the bottom
from a 9 oz paper cup, placing a damp porous sponge into
the cup, and wrapping the molding bag opening around the
cup once the FIPS mixture has been poured into the bag.
Secure the bag to the cup with a rubber band, and drape
the bag away from the client and attendants. The damp
sponge will neutralize any fumes, and reduce the fume level
to zero by absorption. An activated charcoal filter may be
added to the vent as an extra precautionary measure.
Excepting gross mishandling or the use of large quantities,
the Liquid SunMate® FIPS product and process provided by
Dynamic Systems, Inc. is safe without the need for taking
extraordinary precautions. However, the simple and inexpensive optional safety measures listed above may be followed as
safety personnel deem necessary.
Additionally, an inspection performed by OSHA at Dynamic
Systems, Inc. on August 14 and September 3, 1997, showed no
detection of MDI present during the manufacture of Liquid SunMate® FIPS or SunMate®. The permissible exposure limit (PEL)
ceiling is 0.2 ppm.
Liquid SunMate® FIPS Instruction Manual 19
Appendix D – Cold Weather Heating Instructions
Shipping and storage during the winter months may expose the product to temperatures below 50°F. The
FIPS chemicals are formulated to be used at room temperature (between 60°-75°F). If the container feels
cold to the touch, or the chemicals appear thick, cloudy or crystallized, the chemical reaction will be slow
and incomplete. The chemicals may be brought back to the proper consistency using a simple hot water
bath. Follow the instructions below to ensure a good foam rise.
DO NOT HEAT CHEMICALS IN A MICROWAVE OR DIRECTLY ON A STOVE OR HOT PLATE.
Bowl Pack
Heating the Polyol
• First, remove the foil safety seal underneath the lid and loosely place the lid
back on the container.
• Place the Polyol container in a pan of
water preheated to 120-150°f and let it
sit for 15-20 minutes.
• Remove the container from the bath and
let it cool to room temperature.*
• Once the Polyol has cooled, use the
wooden mixing stick to scrape any sediment from the bottom and sides of the
container, then thoroughly mix the Polyol
with an electric beater for 2 minutes.
Heating the Iso

remove foil
and loosen lid
• First, remove the foil safety seal underneath the lid, and loosely place the lid
back on the container.
• Place the Iso container in a pan of water
preheated to 120-150°f, and let it sit for
15-20 minutes until the Iso appears the
same color and consistency as apple
juice. To avoid exposure to possible
fumes, do not exceed 150°f.
• Remove the container from the bath and
let it cool to room temperature.*
Remove the foil safety seal and loosen the lid of
the container when heating the Polyol or Iso.
You must let the chemicals return to room temperature (60-75°f) before using. If the chemicals are too warm,
the chemical reaction will be excessively fast and hot during the molding process.
Bag Pack
You cannot visually check the Iso or Polyol inside the foil bag, so it is a good idea to follow the Cold Weather Heating instructions any
time the Bag Pack has been exposed to temperatures below 50°f.
Heating the Iso
Heating the Polyol
• Place the Iso section of the Bag Pack in
a pan of preheated water (120-150°f),
and let it sit for 10-15 minutes. Do not
exceed 150°f.
• Take the Bag Pack out of the bath and
let it cool to room temperature.*
• Place the Polyol section of the Bag Pack
in a pan of water preheated to 120-150°f,
and let it sit for 15-20 minutes until the
bag feels soft and pliable.
• Take the Bag Pack out of the bath and
let it cool to room temperature.*
• Before use, massage and knead the
Polyol section of the bag for about 2
minutes until the consistency feels
uniform.
Place the Iso or Polyol section of the Bag Pack in a
hot water bath to melt any crystals.
• Cloudy or cold
Iso will not react
properly.
• Heat carefully per instructions.
• Return to room
temp. (65-75°F)
before using.
20 Liquid SunMate® FIPS Instruction Manual
Temperatures
Below 50°F
Crystallize Iso
Heat Carefully
per Instructions
Manufacturing Facility
104 Morrow Branch Rd, Leicester, North Carolina 28748 USA
Hours of Operation
8:00am - 5:00pm EST, Monday-Friday
Telephone
Toll Free: 1-855-SUNMATE (786-6283)
Local: 828-683-3523
24-Hour Fax
Toll Free: 1-844-270-6478
Local: 828-683-3511
Customer Service
[email protected]
[email protected]
www.sunmatecushions.com
MADE IN THE USA
FIPS Manual
150519-R
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