Processes for making molded flexible foams and flexible foams produced thereby

A process for making a molded flexible foam, comprising:

• (a) depositing a foam-forming reaction mixture onto a surface of a mold cavity, and
• (b) allowing the foam-forming reaction mixture to react in the mold cavity, wherein the foam-forming reaction mixture comprises:
• (1) a polyisocyanate present in an amount of less than 45% by weight, based on the total weight of the foam-forming reaction mixture;
• (2) an isocyanate-reactive composition comprising (i) at least 80% by weight, based on the total weight of polyol in the isocyanate-reactive composition, of a polyether polyol (I), polyether polyol (I) having a functionality of greater than 2, an oxyethylene content of 0 to 50% by weight, based on the total weight of polyether polyol (I), more than 50 mol % of primary OH groups, and an OH number of 8 to 112 mg KOH/g;
• and (ii) an amine-initiated polyether polyol with at least two isocyanate-reactive hydrogen atoms and with a molecular weight from 62 to 399 g/mol;
• (3) a blowing agent comprising water present in an amount of at least 0.5% by weight, based on the total weight of the foam-forming reaction mixture;
• and
• (4) a tin-free metallic catalyst composition comprising a bismuth-based catalyst and a zinc-based catalyst.