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Hi, I think I'm going to get started on a desert based terrain board with a couple dunes. Anyway, I was thinking of using expanding polyurithane insulation like Great Stuff to make the dunes and/or base layer. The idea is to get a organic surface that will hopefully still be playable. I am thinking of trying to get a flat part by making some stripes of the stuff and then trying to flaten it out to be more or less a layer of it, then let it expand.

So, do people have any experience with this with terrain or even just using it for its intended purpose to give me any hints or to tell me no way that it will ever work.

There are 2 types of great stuff one is white and too soft. the other is yellow and once it dries it has a hard coat and soft inside. You would be better off using pink or blue foam.
Below are some photos of a table I am building using great stuff for the cave walls and waterfall cliff area. As you see it comes out of can like that and does not shape well I cut it with knife then textured using flexible floor patch (this is great over blue/pink foam as well.)
Hope this helps and saves you some time and money.

Thanks for the pictures and advice, did you get the walls by just making a thick part and letting it expand or having a wall in there and then coating it with this stuff?