Method of deforming a microcellular polyurethane component

A method of deforming a component comprising the steps of:

• forming the component from a liquid reaction mixture into a thermosetting, elastomeric microcellular polyurethane in a solid and partially cured state before all chemical reactions of the microcellular polyurethane are complete and having a pre-deformation density between 300 Kg/m3 and 700 Kg/m3, the component extending along an axis and including a first portion and a second portion each disposed along the axis,
• heating at least a first portion of the component to a first temperature while the microcellular polyurethane is in the solid and partially cured state before all chemical reactions of the microcellular polyurethane are complete,
• compressing the first portion of the component in a direction along the axis while maintaining the first portion of the component at the first temperature and while maintaining the second portion of the component at an undeformable state to permanently collapse cell walls of the microcellular polyurethane of the first portion to shape the first portion of the component and to permanently increase a density of the first portion of the component to between 450 Kg/m3 and 1050 Kg/m3 and while maintaining the second portion of the component at between 300 Kg/m3 and 700 Kg/m3, and
• curing the microcellular polyurethane from the partially cured state to a fully cured state after the first portion of the component is compressed.