With the world evolving towards the use of polymers, there has been an increasing demand to develop high performance, eco-friendly polyurethane (PU) foams for sustainable manufacturing. Herein, three novel studies were carried out to fabricate bio-based PU with natural fillers. The goal of these studies was to enhance the mechanical properties of foam while maintaining high quality and scalability. Initially, natural fillers including chitin, chitosan, lignin, polysaccharide, and hazelnut were embedded into free-rise PU foam to improve the mechanical properties. Consequently, this study helped identify the ideal formulation techniques to fabricate molded foam plaques embedded with hazelnut, chitin, cellulose, and eggshell. These composites were tested against the pure formulation to measure improvements in properties. They were characterized using mechanical, thermal, and morphological analyses to measure the scale-up potential of natural fiber-based PUs. In the last study, alternative reagents and formulation adjustments were made to see how they impact foam properties.