Abstract: A process for casting a foamed mattress having a crown area with cored-out areas therein to modify the harshness of feel of said mattress. A mold cavity having gates therein to give the cored-out pattern in the crown of the mattress is provided and a liquid foamable urethane resin reaction mixture is deposited and distributed in a fan-shaped arc in the cavity from preferably two or more distributing beads in response to the relative movement of the depositing and distributing means to that of the mold. The deposited mixture is then permitted to foam in order to fill the mold and to their cure prior to removing the product from the mold cavity.

Abstract: A contoured foam seat characterized by having a foamed seat and back member with grooved-out portions to give a raised area whereby the seat has contoured body fitting aspects.

Abstract: A foamed article having zones of varying hardness is prepared by moving a shaping means relative to at least two foam pouring means to distribute a foamable mixture over the surface of the shaping means in a fan-shaped pattern in response to the relative motion between the pouring means and the shaper, adjusting the fan-shaped pattern to define zones in the foamed article having the desired physical characteristics.

Abstract: A foam mattress having a crown area with cored-out areas therein to modify the harshness of feel of said mattress.