Products in Core Materials

Toray Toray MicroPly™ SC72A is a 120°C (248°F) curing low-density unsupported epoxy syntactic core. Toray MicroPly™ SC72A offers reduced processing, a one-shot cure, the ability to anchor inserts or fastenings, and increases the opportunity to consider lightweight, thin-walled composite sandwich structures. Considerable cost reductions can be realized when SC72A replaces prepreg as the core material, and where sandwich cores below 3 mm are difficult to achieve in honeycomb core, Toray MicroPly™ is a superior alternative. Toray MicroPly™ SC72A is available in a variety of thicknesses down to 1 mm and is easily contoured and shaped. SC72A is supplied on a roll (15 m x 400 mm) or in sheets (625 mm x 400 mm). Toray MicroPly™ SC72A is compatible for co-cure with Toray E720 and E722 mid temperature curing prepregs.

The special chemical composition, structure and blowing agent of Crio foam give the foam excellent thermal insulation performance, which can save 20% of energy compared with ordinary rigid foam and has good flame retardancy. Mainly used in refrigeration, transportation and other fields.

Kayco Composites R25 is a rigid, closed-cell, high-density polyurethane foam core panel. The reinforced panel is a sandwich construction with fiberglass reinforcements. The fiberglass reinforcements are offered in several schedules.

The sandwich panel is a sandwich structure composed of upper and lower skins and core materials. The upper and lower skins and the lightweight honeycomb core are made of thermoplastic materials, which can make the sandwich panel have the characteristics of light weight, high strength, and recyclability.

Soric® XF 6 is the cost effective solution for closed mold processes. It is used as core material and infusion medium. It is a pressure stable polyester nonwoven and compatible with all regular types of resins, including Polyester, Vinylester, Phenolic and Epoxy. It is suitable for closed mold processes, including Infusion, RTM Light, RTM Heavy.

Divinycell HM is a high performance structural core designed for fast marine hulls where higher toughness is required. Divinycell HM combines a very high shear strength with an outstanding shear elongation. As a result, Divinycell HM is an extremely tough product, capable of absorbing high dynamic impacts and slamming loads. Divinycell HM´s elongation exceeds the requirements of ISO 12215, GL and ABS rules to allow for reduced safety factors in structural calculations, providing a lighter, yet strong structure. Divinycell HM’s high compressive properties provide excellent resistance to denting and skin wrinkling of thin skins. Divinycell HM offers a high operating temperature, thus reducing the risk of print through on dark hulls.

Ultracor UCF-180-3/8-3.5 is available as a honeycomb core with distinctive cell geometry. UltraFlex provides similar or higher mechanical properties than comparable hexagonal cores of equivalent density.

Nomex® AHN-4120-1/4-1.5 is an Aerospace Grade Nomex® Honeycomb which exhibits high strength and toughness in a small cell, low density, non-metallic honeycomb. It is particularly noted for its corrosion resistance. This material is fire resistant and is typically used in transport aircraft construction where low O.S.U., smoke, and toxicity characteristics are a necessity. This material also exhibits good thermal insulation properties and also has good dielectic properties. This honeycomb is easily machined, formed, and shaped and well suited to adhesive bonding.

Plascore Aramid Fiber PN1-1/8-6.0-OV is a commercial grade aramid fiber honeycomb is manufactured from Meta-Aramid paper and coated with a heat resistant phenolic resin.

Barracuda Advanced Composites Divinycell H45 DCI is a rigid PVC foam 45 kg/m³ with DCI cut for vacuum infusion ideal for sandwich structures with high rigidity (80 x 60 cm).

Alveosoft is a crosslinked polyolefin foam produced in a continuous process. It is exceptionally soft, its cell structure is homogeneous, fine, and partially open-celled, its foam skin is water repellent. Alveosoft boasts excellent air sealing at low compression, excellent thermal insulation properties, and high resistance to aging.

SynFoam UL is a 100% closed cell, low density foam with exceptional compressive and insulation properties. UL grade foams are rigid, easily machined and can be sanded to a smooth finish. SynFoam UL is used for structural weight reduction, thermal insulation and as a replacement for honeycomb structures in aerospace applications. SynFoam is also used in the marine industry when a protective coating is applied to prevent water ingress. SynFoam UL is an ideal structural core material and has been used to replace honeycombs, PU and PVC based foams. SynFoam UL is chemically stable and UV resistant. SynFoam UL is available as 6” x 12” x 24” fully cured blocks. The blocks may be further machined into different sizes and shapes by the end user to meet the necessary specific tolerances and requirements. Our syntactic foam is easily bonded together with the use of our syntactic adhesive to form large structures. If you have a specific design for use with SynFoam UL we also provide final fabrication services. Services include machining, assembly, and finishing with a quality coating.

Kayco Composites U20 is a rigid, closed-cell, high-density polyurethane foam core panel. It is a foam with no reinforcement.

Nidaplast EP-S 400 is a easy to transport and use, it allows simple installation and rapid loss of soaks, drainage trenches, etc.

Plastazote® is a closed cell, cross-linked polyethylene block foam manufactured using Zotefoams unique production process.Plastazote® 5SHD30BK-0220 is a high density polyethylene foam.

PAA-SFH® PAA-SFH® (Phosphoric Acid Anodized-Showa Flexible Honeycomb) 3.1-5052-19 is an aerospace grade 5052 aluminum honeycomb materials produced from phosphoric acid anodized aluminum sheets. Phosphoric acid anodize gives an excellent corrosion resistance to aluminum alloy, and the surface treatment system with a corrosion prohibited primer provide the greatest bondability and fatigue strength under critical conditions such as hot & wet condition.

Rock West Composites NOM-0085-24-D is a Aerospace grade aramid fiber honeycomb that exhibits outstanding flammability properties. It is manufactured from Meta-Aramid paper and coated with a heat resistant phenolic resin.

ARPRO® 3437BLFR is a fire retardant expanded polypropylene.

Cel Components S.R.L. Pet/W GR100 is a polyethylene ter based structural foam cores. It is made from 100% post-consumer PET. Pet Foam is a thermoplastic core material suitable for a variety of sandwich applications to increase performance and reduce weight. It is used in sandwich panel applications in railway wagons and in shipyards and for wind power applications. It is easy to work with and has good dimensional stability at elevated temperatures. It is suitable for a variety of processes including infusion, prepreg and pressing.

Soric® XF 2 is the cost effective solution for closed mold processes. It is used as core material and infusion medium. It is a pressure stable polyester nonwoven and compatible with all regular types of resins, including Polyester, Vinylester, Phenolic and Epoxy. It is suitable for closed mold processes, including Infusion, RTM Light, RTM Heavy.

Corrosion resistant HexWeb® Rigicell™ is manufactured by bonding together corrugated sheets of treated 5052 aluminum. This process allows fabrications of much higher density honeycomb than is possible by the expansion process. The node bond adhesive is a thermosetting type. Slices are cut from the corrugated block to specified thickness, length, and width.

Divinycell H provides excellent mechanical properties to low weight. The unique IPN chemical structure, yields impressive mechanical performance to a low weight. Divinycell H has been widely used and has a proven track record in virtually every application area where sandwich composites are employed including the marine (leisure, military and commercial), land transportation, wind energy, civil engineering/infrastructure and general industrial markets. Divinycell H is ideal for applications subject to fatigue, slamming or impact loads. Other key features of Divinycell H include consistent high quality, excellent adhesion/peel strength, excellent chemical resistance, low water absorption and good thermal/acoustic insulation. Divinycell H is compatible with virtually all commonly used resin and manufacturing systems.

SynFoam FP-3 is a two part, closed cell foam in place polyurethane resin system. Upon mixing the A and B side, the system will expend to the final density and rapidly cure to form a rigid structure. When cured FP-3 will provide a rigid structure that is capable of high temperature use up to 135o C. FP-3 is suitable for the encapsulation of electronic modules, rockets, satellites, and antennas. In has been used as a direct replacement for the discontinued Eccostock FPH.

ArmaPET™ Struct FR70 is self-extinguishing version of ArmaPET Struct, we offer a structural foam core designed for applications with particularly stringent fire protection requirements.

Bio-Lux Max™ BLMS18521 is the premier choice when you require a wide range of high performance foams that contain the highest amount of renewable materials on the market. As a recognized leader in environmental stewardship within the polyurethane industry, NCFI has been at the forefront of producing flexible foam products containing renewable raw materials. It is a revolutionary product that is USDA certified at33% bio based content, and is FR free. It is a culmination of years of research and state of the art manufacturing, coming together to produce an environmentally responsible foam without sacrificing performance. Our pledge is to constantly maximize the renewable content of these products while maintaining the high standards you expect.

AIREX® T92 is a closed-cell, thermoplastic and recyclable polymer foam with very good mechanical properties and an outstanding price / performance ratio. It has an extraordinary resistance to fatigue, is chemically stable and has negligible water absorption. It is thermally stable during high temperature processing and post curing without after expansion or out-gassing. T92 is designed for easy use with all resin systems and processing technologies. AIREX® T92 is ideally suited as a core material for a wide variety of lightweight sandwich structures subjected to static and dynamic loads and/or exposed to elevated temperatures during manufacturing

ARPRO 5920 appears in a black color.

Toray Toray MicroPly™ TCF4035 is a syntactic film compatible with 121°C (250°F) epoxy prepregs. It features a 30-day out time and is offered in a density of approximately 0.6 g/cc (40 ± 4 pounds per cubic foot). It features a higher service temperature than Toray TCF4025. Syntactic Epoxy Film.

SynFoam HT is a high performance, light weight pre-cast syntactic foam that provides the best combination of high temperature resistance and dielectric properties. SynFoam HT has a low coefficient of thermal expansion and good strength. In addition to being used for weight reduction SynFoam HT is also used in the microwave industry because of the dielectric properties which show outstanding performance over a wide frequency range up to 10 GHz. SynFoam HT is an ideal structural core material for applications that will be exposed to higher temperatures and has been used to replace honeycomb structures. SynFoam HT is chemically stable, UV resistant and does not absorb water. SynFoam HT is available as 4” x 12” x 12” fully cured blocks. The blocks may be further machined into different sizes and shapes by the end user to meet the necessary specific tolerances and requirements. Our syntactic foam is easily bonded together with the use of our syntactic adhesive to form large structures. If you have a specific design for use with SynFoam HT we also provide final fabrication services. Services include machining, assembly, and finishing with a quality coating.

Divinycell HP has been developed to meet demands in high temperature systems, and low temperature prepreg systems. The unique IPN chemical structure, yields impressive mechanical performance to a low weight. Divinycell HP´s elevated temperature performance also extends to its ‘in service’ life as it will retain a high percentage of its mechanical properties despite exposure to high ambient temperatures. It offers high properties in all significant areas including mechanical performance, elongation to break, ductility, adhesion/peel strength, fracture toughness and dimensional stability. Other key features of Divinycell HP include excellent chemical resistance, low water absorption and good thermal/acoustic insulation.

Evazote® is a closed cell, cross-linked ethylene vinyl acetate copolymer block foam manufactured using Zotefoams unique production process. Evazote® 5SEV50BK-0186 is a ethylene vinyl acetate copolymer foam.

HexWeb® HFT® is a fiberglass ± 45 degree Fibertruss® bias weave reinforced/phenolic honeycomb. This bias weave construction enhances the shear modulus properties of the honeycomb core. The shear modulus for HexWeb® Fibertruss® HFT® is about twice that of HRP® (honeycomb made of straight weave fiberglass) and three times that of HRH® -10 (honeycomb made from NOMEX® ). This makes HexWeb® Fibertruss® HFT® honeycomb ideal for applications where minimum deflections are required. There is little change in flatwise compression properties due to the bias of the glass. HexWeb® Fibertruss® HFT® has improved damage resistance and handling since the 45 degree angle of the fiber at the cell wall corners allows greater flexibility. This increased flexibility allows the HexWeb® Fibertruss® HFT® to be formed more easily than straight weave honeycombs, resulting in reduced shop losses and simplified fit up of parts during assembly. HexWeb® Fibertruss® HFT® has improved node bond strength and flexibility that makes it possible to offer a 1/8-inch cell fiberglass reinforced honeycomb. This, together with the higher shear properties, makes HexWeb® Fibertruss® HFT® an excellent core for use with high modulus graphite or other composite facing materials. The potential problem of galvanic corrosion with untreated aluminum honeycomb is eliminated, and the small cell size provides uniform support and bonding area for such facings.

SynFoam EFC is a two part closed cell syntactic resin system that is based on epoxy rather than polyurethane chemistry. SynFoam EFC provides far greater strength, stiffness, impact absorption, and shear properties than standard core materials. SynFoam EFC will not absorb resins or other materials making it a good selection for use in RTM, vacuum bag, pultrusion or other composite applications. SynFoam EFC has good resistance to heat and is resistant to water, hydrocarbon fuels, and chemicals. It has excellent adhesion to metals and can be used as a gap filler or to promote metal to composite bonding. SynFoam EFC is shipped as two components which when mixed together can be poured and cast into various shapes and sizes. SynFoam EFC is available in 1 and 5 gallon kit sizes. Each kit contains an A and B side that must be mixed together prior to casting. The B side selection is dependent on the final use temperature for the material. EFC can maintain its rigidity between 100 and 150oC depending on the selected curative. SynFoam EFC does not require temperature to cure, but requires higher postcure temperatures to reach the maximum service use temperature. Please consult the appropriate instructions prior to using EFC. SynFoam provides custom fabrication of parts and can cast SynFoam EFC to size. Please contact us for more information on fabrication services.

ARPRO 5135 appears in a black color.

CORRITE™ SF-150, a product of I-Core Composites, LLC (I-CORE), has a proven track record of successful application in a wide variety of structural applications. I-CORE products are designed and manufactured to meet customer specifications and custom products are available upon request.

CELLOMER® PELLETS 2100DR is a hot-pressing or injection foaming boards featuring anti-slippage and elasticity. Having adjustable stiffness when mixed with MCC’s other special high polymer materials.