Dureflex film is processed in a variety of ways, combining and converting materials into high performance parts and products.

Autoclave processing is used to combine similar or dissimilar, rigid materials by melting flexible adhesive interlayers under pressure to create a composite structure. For example, to produce impact resistant transparencies, the rigid and adhesive layers of optical aliphatic polyurethane, known as the lay-up, are stacked. Air is removed between layers via vacuum or pressure nipping, and the lay-up is placed in an autoclave. The lay-up is subjected to carefully managed temperature and pressure profiles, including the specific ramp-up, hold, and ramp-down periods, collectively referred to as the autoclave cycle. This process creates a composite transparency that, after cooling, has impact resistant properties much greater than those of any individual layer. Dureflex aliphatic polyurethane sheet serves as the flexible, durable adhesive that absorbs the stresses created during the cooling of dissimilar materials, reducing the potential for shattering of glass or warping of other components. In addition, the adhesive enhances the mechanical and physical shock absorbing properties of the transparency. Applications where Dureflex film may undergo autoclave processing include: impact, ballistic, blast, and / or hurricane resistant transparencies for military, government, police, correctional facilities; financial institutions; armored vehicles; aerospace.

Die cutting, punching, and stamping are mechanical processes used to fashion parts into predefined shapes or sizes. Applications where Dureflex film may be die cut, punched, or stamped include: labels; wound dressings; EKG pads; emblems; gaskets; patches; metal bending; surface protection; containment suit components; glove box ports; inflatable parts; paint protection; hydration reservoirs; shoe insoles; padding; and membrane switches.

Flame lamination creates a bond by passing soft foam over an open flame, producing a thin layer of molten polymer that becomes the adhesive for bonding polyurethane foam to polyurethane film. The foam lamination process is most frequently used to create laminates that are die cut into parts. Applications where Dureflex film may be flame laminated include: automobile headrests; armrests; sound deadening constructions; motor housing insulation; automotive carpet backing; shoe inserts; automobile seating; headliners; and visors.

The foam-in-place process is a reaction of polyurethane chemicals that creates foam, which is used to fill voids in either a cut-and-sewn laminate part or between two parts of a mold. In cut-and-sewn parts, the Dureflex polyurethane film serves as a barrier to prevent the reacting polyurethane foam from penetrating the laminate. As the foam fills the void, it bonds with the film on the inside of the cut-and-sewn laminate, giving the outer laminate skin a tight fit to the foam. In molded parts, the film is stretched into all contours of the mold as the foam expands, providing excellent protection to the mold from the polyurethane chemistry. Additionally, it provides a well-bonded moisture and contamination barrier for the final foam part. Applications where Dureflex film may be used with foam-in-place technology include: seat cushions; headrests; armrests; shoe inserts; and architectural moldings.

Heat sealing, or hot platen sealing, joins Dureflex film or composite laminates by heating areas under pressure until fusion occurs. Applications where Dureflex film may be heat-sealed include: bags; mattresses; letters and numbers for uniforms and clothing; condoms; prostheses; probe sheathing; and flexible / reinforced industrial hose.

Hot melt lamination combines Dureflex film with woven, non-woven, and knitted fabrics, as well as other substrates, by applying heat and pressure. These laminates have improved physical strength for wear, puncture, and tear resistance, and have excellent barrier properties that provide water resistance and breathability. The finished laminate possesses the complementary properties of both the polyurethane film and the fabric. Dureflex film can also be used as a flexible adhesive with significant tensile properties, bonding numerous numbers of materials in a composite structure. Applications where Dureflex film may be hot melt laminated include: automobile cabin head liners; seam seal tapes; inflatable rafts; blood pressure cuffs; emblems; labels; breathable apparel; bullet resistant vests; smart cards (e.g., credit, debit, identification, etc.); radio frequency identification (RFID); conveyance belting; drive belting; and cured in-place pipe rehabilitation (CIPP).

Pressure thermoforming is the process of forcing a heat-softened Dureflex sheet against a mold with compressed air. The applied pressure is typically several times greater than that of vacuum thermoforming, and results in the formation of highly detailed parts and finishes. When cooled, the material is removed, having taken the shape of the mold. Dureflex sheet provides the necessary flexibility for three-dimensional draw range that goes beyond typical design boundaries. Applications where Dureflex film may be pressure formed include: in-mold decorative blanks; automotive seats; and cushions.

Radio frequency welding or sealing, also referred to as dielectric high frequency (HF) welding or sealing, uses a rapidly alternating, high-energy electromagnetic field to stimulate the molecules of two overlapping layers of standalone or laminate constructions. The stimulated molecules create localized heat, causing the two layers to fuse together at the point of contact, creating a weld. After the weld cools, the bond is as strong as the original materials. Applications where Dureflex film may be RF welded or sealed include: protective clothing; shoe components; gel- and foam-filled cushions; surgical pouches; bellows; lumbar support; hydration reservoirs; inflatable boats; and medical and commercial mattresses.

Solvent lamination is widely used to improve or modify the physical properties and appearance of fabric, or to create composites that offer the advantageous characteristics of the combined materials. During the process, a solvent-based adhesive system is used to solvate the Dureflex film, which then bonds to the textile. This process enables laminators to combine complementary materials, achieving various product advantages. Applications where Dureflex film may be solvent laminated include: multilayer textile laminates; breathable clothing; wound dressings; belting; life vests; and rafts.

Solvent welding or bonding joins the surfaces of standalone or composite laminates. When solvent is applied to the Dureflex polyurethane film, it causes the surface to soften and swell. As pressure is applied, the solvent evaporates and the two surfaces bond together without the use of adhesives. This welding method is particularly good for heat-sensitive constructions that would otherwise be damaged or destroyed by other welding techniques. Applications where Dureflex film may be solvent welded include: recreational watercrafts and surgical drapes.

Vacuum thermoforming draws a heat-softened Dureflex sheet into a female mold by creating a vacuum between the inside of the mold and the material. When cooled, the material is removed, having taken the shape of the mold. Applications where Dureflex sheet may be vacuum thermoformed include: decorative moldings; packaging; speaker cones; shoe insoles; in-mold inserts to make soft touch automobile instrument panels; in-mold decorating blanks; keyboard covers; tray covers; and liners.