The structural foam core material
AIREX® foams provide your sandwich structures with that much-sought-after combination of strength, stiffness and minimal weight. Besides thermal insulation on top. When used as a core material between two thin, stiff face sheets AIREX® foams create rigid sandwich structures that can be more than 50% lighter than conventional solutions.
Moreover, weight savings due to sandwich constructions with AIREX® core materials enable the launch of a positive spiral: low inertia equals less power needed to move, power savings that translate into even lower weight.
Besides, weight savings thanks to sandwich constructions with AIREX® core materials allow switching mass from dead weight to payload instead.
In the wind energy market, AIREX® foams permit a lower weight-to-stiffness ratio which opens the door to bigger wind turbine blades, in turn leading to increased energy conversion performance.
- Extremely low specific weight
- High mechanical rigidity and stiffness
- Good fatigue resistance
- Excellent chemical resistance
- Good compressive and shearing properties
- High bending resistance and rigidity
- Impact strength
- Easy processing
- Good face sheet adhesion
- High temperature resistance
- Good fire inhibition
- Low water absorption
- Low resin absorption
- Dimensionally stable
- Renewable energy
- Building & Construction
All of our AIREX® foams are very easy to process. From simple blank cuts to complex sets or thermoformed components with complex 3D shapes – AIREX® core materials are very easy to shape.
Processing into a sandwich is effortless and the material is suitable for all commonly used production methods, e.g. hand lamination, resin infusion, prepreg, RTM, etc. Our processing guidelines include all relevant information regarding processing of the core materials we offer. They are a valuable tool for successful utilization of AIREX® foams.
Core material finishing options are an important part of our product offer. They are a significant factor in the processability of our materials as well as the costs, weight and the quality of the final product. Therefore we offer an extensive range of state-of-the-art finishing options.
The perfect selection of finishing options will enable you to optimize the following criteria during processing and in the final product:
- Handling during production
- Resin absorption
- Process speed (resin flow rate during infusion)
- Laminate infusion
- Surface quality
Industrialized structural PET foam core
AIREX® T10 is a closed-cell, thermoplastic and recyclable polymer foam with a very homogeneous cell structure, high mechanical properties and an outstanding price / performance ratio. It has extraordinary resistance to fatigue, is chemically stable, UV-resistant and has negligible water absorption. It is thermally stable during high temperature processing and post curing without showing after-expansion or out-gassing.
High performance structural FST foam
AIREX® R82 is a thermoplastic rigid foam with excellent fire resistance, low smoke emissions and toxicity. Other superior features are its outstanding dielectric properties, excellent stiffness to weight ratio, low water absorption and high durability. AIREX® R82 can be thermoformed to simple 3D structures and is highly suitable for structural sandwich components with stringent fire requirements, excellent radar transparency or in extremely hot or cold environments.
Easy processing structural FST foam
AIREX® T90 is a closed-cell, thermoplastic and recyclable, structural PET rigid foam with excellent fire, smoke and toxicity (FST) properties. It is suitable for lamination with all types of resins and processes and is easy to process mechanically and to thermoform. It is also resistant against UV rays and chemicals and does not absorb water. Curing and post curing at increased temperatures are unproblematic as it is highly heat-resistant without showing after-expansion or outgassing.
Easy processing structural PET foam
AIREX® T92 is a thermoplastic structural rigid foam with closed cells and is highly suitable for lamination using all types of resins and processes. The AIREX® T92 manufacturing process results in a structural core material with very consistent properties. Shear strain/damage tolerance is highly improved and allows utilization in a majority of structural sandwich constructions. The foam is very easy to process mechanically, can be thermoformed and is highly heat resistant. AIREX® T92 is ideal for use with various prepreg systems at high temperatures. It is very chemically stable, shows no water absorption or post-expansion.
Fiber-reinforced structural foam
AIREX® PXc is a closed-cell, fiber-reinforced urethane foam with special formulation that offers significant advantages in comparison to conventional sandwich core materials. A special manufacturing process is used to distribute continuous fiberglass filaments evenly in the PXc foam. This creates a very smooth product with excellent compressive and shearing properties. The foam is dimensionally stable, shows low water absorption and is resistant to chemicals and high temperatures. AIREX® PXc is an ideal core material for sandwich elements subjected to high stress loads or as a substitute for wood and plywood.
Fiber-reinforced sheet of structural foam
AIREX® PXw is a closed-cell, fiber-reinforced urethane foam with special formulation that offers significant advantages in comparison to conventional sandwich core materials. A special manufacturing process is used to evenly distribute continuous fiberglass filaments with mesh in the foam. This creates a product with increased bending resistance and rigidity, which enables utilization with and without face sheets. The foam is dimensionally stable, maintains stiffness even when subjected to moisture and is resistant to chemicals and high temperatures. AIREX® PXw is an ideal core material for static applications requiring a high level of rigidity or as a substitute for wood and plywood.
Industrial processing foam
AIREX® C51 is a closed-cell rigid foam designed to be used in industrially manufactured sandwich components in large quantities. The foam has high ultimate strain and is also characterized by excellent impact strength and fatigue resistance. It can be formed to simple 3D structures at room temperatures, but can also be thermoformed to more complex 3D structures. The increased temperature resistance allows manufacturing processes with short cycle times and fast-hardening resins or fiber-reinforced thermoplastic face sheets (GMT). AIREX® C51 is a suitable core material for mass-produced sandwich products with static or dynamic load.
Universal structural PVC foam
AIREX® C70 is a closed-cell, cross-linked rigid foam with excellent rigidity and a great stiffness to weight ratio. It is highly durable, has a low water absorption rate and excellent chemical resistance. It can be processed with all commonly used resin systems and processes. The fine cell structure supports excellent adhesion of face sheets. AIREX® C70 is the ideal core material for many lightweight sandwich structures subjected to dynamic or static loads.
Elevated temperature structural foam
AIREX® C71 is a closed-cell, cross-linked rigid foam with high temperature resistance, excellent rigidity and a great stiffness to weight ratio. It is extremely durable, has a low water absorption rate and excellent chemical resistance. It can be processed with all commonly used resin systems and processes. The fine cell structure supports excellent adhesion of face sheets. AIREX® C71 is the ideal core material for lightweight sandwich structures for dynamic or static loads subjected to increased temperatures.