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"Our company was founded in 1966 as a R&D facility focusing on advances in plastics technologies. In 1998, our company won an award to develop a state of the art syntactic foam to provide improved buoyancy at a lighter weight. This small project eventually led to the development of four grades of Synfoam HP, our first commercial syntactic foam offering. Since that time our company has continued to focus on improving the properties of syntactic foam to both lower costs and enhance the performance for our valued customers. Our company prides itself on working closely with our customers to custom formulate solutions for their various projects.
Synfoam now offers over 50 off the shelf syntatcic foams that have found use in many industries beyond the typical subsea uses that most associate syntactic foam with. We are fully staffed with engineers, scientists, and a manufacturing team to meet the demand for Synfoam and help maintain strict quality controls over our syntactic foam. We are in the process of becoming ISO 9001 certified to further our commitment to operational excellence. Our offices and manufacturing facility are located in Livingston, NJ."

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Syntactic foam is a high strength, light weight material that is created by using hollow spheres, typically made of glass, that are bound together with a thermoset polymer. The use of the word foam can be misleading as many people when they think of foam think of something that is weak and flexible. Here the word foam related to the cellular structure of the material, but SynFoam is a material that has incredibly high strength and modulus that makes it useful for many composite applications. SynFoam syntactic foam, with its unique properties of high strength and low density, is widely used in the subsea buoyancy industry. They provide weight reduction and buoyancy for various underwater applications and resist hydrostatic pressure and long term water exposure up to the depth at which the syntactic foam is rated.

SynFoam

SynFoam MW is a moderate cost, high performance syntactic foam designed for the most critical deep water applications. SynFoam MW has an excellent strength to weight ratio and a better cost/performance benefit than SynFoam DW. MW is typically chosen for use where cost rather than density is the primary factor in selection of syntactic foam for deep water applications. MW is offered in densities between 30 and 44 pounds per cubic foot and provides the performance necessary for standard 5K and 6K ROV's as well as other underwater vehicles where a high strength is required. SynFoam MW 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 MW we also provide final module fabrication services. Services include machining, assembly, and finishing with a quality marine based paint.

SynFoam® MW-30

SynFoam AD s a two component, room temperature curing, castable syntactic designed for casting lightweight complex shapes, where the need for acoustic transparency is a priority. Synfoam AD shows high levels of echo reduction both at ambient pressure and at operating depth. It has been used in the manufacture of sonar domes and sonar windows in submarines. The cast product provides an acoustically transparent housing that surrounds and protects a marine ship’s sophisticated sonar transducer array. SynFoam AD is available as 1, 2, and 5 gallon kits. Each kit contains an A and B side that must be mixed together prior to casting. Cure is achieved within 24 hours and full properties will be realized after 7 days at room temperature. Densities can be customized to the user's specifications. Please consult the appropriate instructions for limitations of depth of cure. If you have a specific mold for use with SynFoam AD we also provide final casting and fabrication services. Services include casting and finishing with a quality paint.

SynFoam® AD-30

SynFoam LG is a unique, expandable, closed cell syntactic foam that provides very low density and moderate strength. SynFoam LG is an ideal replacement for polyurethane foams where higher modulus is needed to support lightweight structures. SynFoam LG has low dielectric loss and loss properties at a reduced weight than traditional low loss materials used for electronic applications. The system is suitable for electronic potting and encapsulation as well as structural support. SynFoam LG is ideal for electronic applications that require room temperature curing temperatures and will not be exposed to high continuous use temperatures. Please see our ELG grade foams for high temperature applications. SynFoam LG is available as one and five gallon kits. Each kit contains an A and B side that must be mixed together prior to casting. Cure is achieved within 24 hours and full properties will be realized after 7 days at room temperature. Densities can be customized to the user's specifications. Interlayer adhesion allowing large structures to be made with multiple pours. If you have a specific mold for use with SynFoam LG we also provide final casting and fabrication services.

SynFoam® LG-15

SynFoam HG is a unique, very high strength castable syntactic foam that provides low density. It is suitable for numerous marine and aerospace applications where machining of parts is either impractical or too expensive. SynFoam HG exhibits low shrinkage and is resistant to water, oils, and fuels. The castable nature of the syntactic eliminates the cost and waste associated with machining. SynFoam HG is provided as a custom cast product that will be made to your specifications. Please contact us to discuss using SynFoam HG with custom molds.

SynFoam® HG-34

SynFoam AI provides a combination of excellent strength and high temperature property retention along with outstanding acoustic properties. SynFoam AI was developed for use in Naval applications conforming to drawing numbers 5819079 and 5856846. SynFoam AI has been used to provide acoustic insulation for prime contractors within the US department of defense. SynFoam AI is available as precast sheets that can be machined to user specifications up to a maximum size of 2" x 12" x 24". SynFoam AI is easily machined into small shapes and can be bonded together if larger structures are required. Custom formulation services utilizing the AI matrix are available and we also provide final machining services.

SynFoam® AI-42

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.

SynFoam® HT-14

SynFoam SW is a pressure resistant syntactic foam designed to provide buoyancy for underwater depths up 1,000 meters. SW is a closed cell foam that is easy to machine and will provide a smooth surface after sanding. SynFoam SW is ideal for underwater robotics, vehicles, flotation, pumps and as a core material. SynFoam SW resists water absorption and provides excellent performance for in shallow subsea applications. It has been used as a replacement for PU and PVC based foams due to its higher strength, better chemical resistance, and UV stability. SynFoam SW 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 SW we also provide final module fabrication services. Services include machining, assembly, and finishing with a quality marine based pain

SynFoam® SW-9

SynFoam DW is a high performance syntactic foam designed for the most critical deep water applications. SynFoam DW has the highest strength to weight ratio of all SynFoam grades and allowing the end users to ultimately reduce the weight of the buoyancy package. Our DW series ranges in density from 31 to 41 pounds per cubic foot and is highly recommended for 5K and 6K ROV's as well as other deep water submersibles. SynFoam DW is available as 4.5” x 11.5” x 11.5” 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 DW we also provide final module fabrication services. Services include machining, assembly, and finishing with a quality marine based paint.

SynFoam® DW-33

SynFoam® AI-44

Synfoam

"Our company was founded in 1966 as a R&amp;D facility focusing on advances in plastics technologies. In 1998, our company won an award to develop a state of the art syntactic foam to provide improved

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SynFoam HTC is a castable syntactic foam that has exceptional dielectric and low loss properties. SynFoam HTC can be used at temperatures up to 180oC and is resistant to water, chemcicals, and hydrocarbon fluids. The castable nature of the product eliminates the need for machining and is suitable for use with standard RTM and mix-meter equipment. The surface finish of parts molded from SynFoam HTC varies from high gloss to matte depending on the finish of the mold. SynFoam HTC has been used in the fabrication of radomes, antennas, reflectors, and radar absorbing coomposites. SynFoam HTC is available as 1, 2, and 5 gallon kits. Each kit contains an A and B side that must be mixed together prior to casting. SynFoam HTC will require a temperature of 150oF to cure with higher postcure temperatures recommended to reach the maximum service use temperature. Please consult the appropriate instructions prior to using HTC. If you have a specific mold for use with SynFoam HTC we also provide final casting and fabrication services.

SynFoam® HTC-38

Radomes

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