Silicone foam is normally considered to be an open cell, lightweight product cast from low-viscosity, liquid silicone ingredients. These ingredients are catalyzed, rapidly mixed, and cast onto a smooth, plastic liner.The cast foam is dispensed in a controlled thickness onto the plastic liner. It is then passed through a curing oven, and post-cured to drive out residual moisture or vapors. The finished product typically has a smoother surface.The lower density grades of cast silicone foams are typically not as successful in harsh-environment testing, such as wind-driven rains. Air and moisture can pass through low density open cell silicone foam unless the design allows for extensive deflection of the gasket.

Higher density silicone foams have been developed in recent years that permit good weather sealing with medium and firm density silicone foam products. These higher density silicone foam products are actually composed of many closed cells. A major benefit of the liquid silicone foam product is the fact that it is flame-retardant, with many products meeting the UL94V0 rating.

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