AIREX®

The structural foam core material

AIREX® foams give your sandwich structures the much desired combination of outstanding strength, excellent stiffness 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 solutions.

AIREX® foams provide you with unparalleled advantages: best-in-class performance, quality and resistance, total cost of ownership, global availability, lean production and innovation.

Sandwich constructions with AIREX® core materials are the road to light, fuel-efficient vehicles. In the wind energy market, AIREX® foams permit a lower stiffness to weight ratio opening the door to bigger turbine blades, which in turn leads to increased performance and sustainability.

Properties
Applications
Processing

Properties

  • 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
  • Non-decomposable
  • Dimensionally stable

Applications

  • Renewable energy
  • Marine
  • Building & Construction
  • Automotive
  • Rail
  • Aerospace
  • Industry

Processing

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
  • Costs

Product range

AIREX® T10

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.

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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 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.

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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 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.

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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 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.

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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 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.

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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 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.

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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 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.

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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 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.

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