The objective of this study is to investigate an appropriate process to fabricate the wood-polyurethane hybrid composites [wood-polyurethane foam (PUF)]. Rigid PUFs that contain up to 20% wood flours were successfully fabricated from polymeric 4,4-diphenylmethane diisocyanate, polyols, silicone surfactant, dibutin dilaurate/dimethylethanolamine catalysts, and distilled water (chemical blowing agent). The effects of hydroxyl value of polyols, wood flour particle size, wood flour content, isocyanate index, and water amount on the compressive property of foam were investigated. The morphology of the cell was observed with a scanning electron microscope. Wood-PUF with different densities were prepared at different water contents in the wood flours. The relationship between the compressive property and density was established following the Power law. The incorporation of wood flour improved the compressive property of PUF, whereas its tensile and flexural properties were reduced. The thermal stability of the PUF was improved with the addition of wood flour. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 113: 2902-2909, 2009