AIREX® Structural foam cores

The product name AIREX® is composed of AIR and EX for expansion. Air bubbles, which are characteristic for this material, form during the manufacturing process and increase the volume many times over - while the weight remains constant.

Specifically, our AIREX® foam products are composed of 50-96% air. This minimizes the consumption of raw materials as well as weight and costs.

AIREX® rigid foams persuade with their very high mechanical properties and minimal weight. When used as a core material between two thin, stiff face sheets they create sandwich structures that can be more than 50% lighter than conventional structures.

Properties

AIREX® - as do all of our core materials - has the following properties:

  • Extremely low specific weight
  • High mechanical rigidity and stiffness
  • Reduced use of raw materials

AIREX® core materials have other specific properties that predestine them to be used in a variety of applications. Among these are:

  • Good fatigue resistance
  • Excellent chemical resistance
  • Good compressive and shearing properties
  • High bending resistance and rigidity
  • Impact strength
  • Easiest processing
  • Good face sheet adhesion
  • High temperature resistance
  • Good fire inhibition
  • Low water absorption
  • Low resin absorption
  • Non-decomposable
  • Dimensionally stable
Applications

When used as a core layer with various shaping options and in various sandwich structures they allow the construction of lightweight yet sturdy elements. Thanks to the plethora of possible combinations, AIREX® is suitable for numerous areas of application:

  • Marine
  • Renewable energies
  • Rail
  • Aerospace
  • Roads
  • Architecture/construction
  • Interior finishing
Processing

All of our AIREX® foams are very easy to process. From simple blank cuts to complex sets or thermo-formed 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 common production methods, e.g. hand lamination, resin infusion, pre-preg, RTM, etc. Our processing guidelines include all relevant information regarding the processing of our core materials. They are a valuable tool for the 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 costs, weight, and quality of the final product. Therefore we offer an extensive range of state-of-the-art finishing options.

The optimum 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
  • Costs
Product range

AIREX® T10 - the industrialised 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 an 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 after expansion or out-gassing.

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AIREX® R63 - damage tolerant foam

AIREX® R63 is a closed-cell, linear thermoplastic rigid foam with extremely high damage tolerance and very durable properties. The foam achieves above-average adhesion of face sheets and can be formed into simple 3D structures without being heated. AIREX® R63 is an excellent core material for dynamically stressed sandwich structures that absorb impact energy.

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AIREX® R82 - 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 the outstanding dielectric properties, the 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.

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AIREX® T90 - 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 thermoform. It is also resistant against UV rays and chemicals and does not absorb water. Curing and post curing at increased temperatures is unproblematic as it is very heat-resistant and does not post expand or outgas.

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AIREX® T92 - 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 most structural sandwich constructions. The foam is very easy to process mechanically, can be thermoformed, and is very heat resistant. AIREX® T92 is ideal for use with various pre-preg systems at high temperatures. It is very chemically stable, does not absorb water, and shows no post-expansion.

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AIREX® PXc - 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 foam. This creates a very even 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 subject to high stress loads or as a substitute for wood and plywood.

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AIREX® PXw - 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 subject 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.

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AIREX® C51 - industrial processing foam

AIREX® C51 is a closed-cell rigid foam designed to be used in industrially manufactured sandwich components in high quantities. The foam has a 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.

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AIREX® C70 - 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 common 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 subject to dynamic or static loads.

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AIREX® C71 - 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 common 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 that are subject to increased temperatures.

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