Foam reaction injection molding (FRIM) is one of the most popular and useful processes for producing polyurethane foam with a complex geometry. A theoretical model which includes chemical reactions, foaming, and mold filling was developed to analyze FRIM. Energy balance equation was derived by considering polyurethane reaction, water-isocyanate reaction, and evaporation of physical blowing agents. Density and viscosity model was proposed for the bubble suspension, which was assumed to be a homogeneous phase. Based on the theoretical model, three-dimensional numerical simulation for mold filling of the polyurethane foam was carried out to predict flow field, flow front advancement, and density distribution during mold filling. Mold filling of a refrigerator cavity was investigated numerically. The density and thermal conductivity of the foam in the flow front was higher than those in the initially filled region. (c) 2005 Elsevier Ltd. All rights reserved.