Design and dimensioning of manufacturing processes based on filling molds with polyurethane foams still require the use of highly empirical approaches. This includes numerous experimental runs with expensive prototypes. Therefore, a method has to be found to analyze the molding process at an early stage of product development to shorten time-to-market cycles and cut costs by using fewer prototypes. With the computational power available today and growing computational power in the future, the tool of choice is the numerical simulation of mold filling processes with computational fluid dynamics software.