This document summarizes research conducted on the sensitivity of process parameters for polyurethane-based panel air filters. Experiments varied parameters like nucleation, mixing speed, mold temperature, mixing ratio, and analyzed their effects on density, hardness, and rise time. Increasing nucleation and mold temperature decreased density and hardness. Higher mixing speeds had little effect with nucleation but decreased density without. Density decreased and hardness was stable at standard mixing ratios but varied above and below. The goal is to define optimized parameter settings to minimize defects for high productivity and yield.