 Polyurethane foams, PUFs, have numerous applications due to their low density, thermal conductivity, and mechanical properties, but their production is highly petroleum dependent and must adapt to regulations and consumer demands for renewable raw materials and new process technologies such as 3D printing. The work reviews the fundamental aspects of PUF production, outlines challenges and process methodologies, presents alternatives, discusses sustainability strategies including recycling and property enhancement. This article was authored by Nuno V. Gama, Artur Ferreira, and Ana Barostimans.