Non‐Lethal Weapons are made and designed proportionately and developed to hinder or expel individuals, with a low probability of fatality or permanent injury, with minimal undesired damage or impact on the natural world. Many real cases show that non-lethal projectiles can lead to severe lesions and sometimes to the death. Consequently, there is a necessity to develop and control the manufacturing of the projectile materials in order to ensure a good effectiveness with a lower injury level. In the present paper, a methodology of elaboration and characterization of filled polyurethane foams is proposed. The proposed methodology tends to control the development of the microstructure leading to the final product with desired properties for non-lethal application. The mechanical characterization was carried out using dynamic tests. A homemade pneumatic launcher and a rigid wall are used for the dynamic characterization. Moreover, a physicochemical characterization of the developed foams was carried out: spectroscopy and XRD analysis, in order to highlight the opened-cell morphology and chemical irregularities, respectively.