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Foam

Foam is most frequently used as structural core material for composite laminates, delivering added strength, stiffness, and insulation, without adding weight. Generally, it is easy to handle, readily conforms to shapes, and can be bonded in layers to add thickness.

Fibre Glast offers a variety of foams, all of which are suited for varying applications that include: flotation; sculpting; cavity filling; flow media in vacuum bagging; and pattern making. Foam can be found in infrastructure applications, wind energy, land transport, and in the marine industry.

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DIVINYMAT
Structural Flow Media

Divinymat has been engineered specifically for the resin infusion process and serves as both a sandwich core and a flow media.

Divinymat is a 3.8-pound DIAB Divinycell H foam. As a foam sandwich core, it provides the highest strength-for-density in its application range, which includes marine and land transportation, wind energy, civil engineering/ infrastructure, and general industrial markets. It also delivers solid compressive and shear strength in both ambient and elevated temperatures.

Cross-scoring, as well as grooves and perforations, at the surface of the foam create controlled flow channels for resin during the infusion process. It offers the highest structural properties of any available flow media.

  • Bonded to a light scrim cloth at its back, allowing it to conform to most simple curves and shapes
  • Compatible with epoxy, polyester, and vinyl ester resins
  • Features chemical resistance, low water absorption, and good thermal/acoustic insulation
  • Store out of direct sunlight

Divinymat is sold by the sheet and is ⅛" thick.

 
Vinyl Foam: Divinycell 3 lb. Density
Lightweight Versatile Foam

DIAB closed cell vinyl foams are valued for their superior structural and mechanical properties. These foams are often used as a structural sandwich core for weight-sensitive aircraft and automotive applications. They combine ultra-low weight, improved stiffness, and impact resistance.

At 3 lb./cubic foot, the density of these foams is similar to that of industry honeycombs, though strength properties do not match up to costlier honeycomb alternatives.

  • Extremely easy to handle, including cutting, shaping, and thermoforming with a heat gun or oven
  • Used to build bulk rapidly, or bond individual sheets to provide additional thickness in target areas
  • Insulative and water resistant
  • Compatible with epoxy, polyester, and vinyl ester resins

The different thicknesses we offer are tailored to different applications:

  • ⅛" thick foam is best used for laminates that require only additional impact resistance or parts with a small cross-section.
  • ⅜" thick foam offers additional strength and impact resistance without adding significant weight; it's well suited for making reinforced vertical components or walls.
  • ½" thick foam offers the highest strength to a composite part.; applications usually include structural components like flooring and exterior paneling.

DIAB Divinycell H45 3 lb. density sheets measure 32" X 48".

 
Vinyl Foam: Divinycell 4 lb. Density
Balanced Weight and Strength

DIAB closed cell vinyl foams are valued for their superior structural and mechanical properties. When used as a structural sandwich core, these foams combine ultra-low weight, improved stiffness, and impact resistance. In particular, our 4 lb./cubic foot foam is employed extensively in marine (leisure, military and commercial) and automotive applications.

  • Extremely easy to handle, including cutting, shaping, and thermoforming with a heat gun or oven
  • Used to build bulk rapidly, or bond individual sheets to provide additional thickness in target areas
  • Insulative and water resistant
  • Compatible with epoxy, polyester, and vinyl ester resins

Many customers experiment with various thicknesses and densities of foam to find the correct balance between part weight and strength. However, each thickness is well suited for a number of traditional applications:

  • ⅜" thick foam offers additional strength and impact resistance to a composite laminate without adding significant weight; it's well suited for making reinforced vertical components or walls.
  • ½" thick foam offers significant strength to a part with a limited impact on overall weight; applications include boat hulls, exterior panels, and other structural components.

DIAB Divinycell H60 4 lb. density sheets measure 32" X 48".

 
Vinyl Foam: Divinycell 5 lb. Density
Highest Strength Foam

Looking to make a strong composite part? DIAB closed cell vinyl foam is an ideal sandwich core where ultimate laminate strength is critical. With compressive strengths over 200 psi, the 5 lb./cubic foot foam offers more strength to a laminate than other lightweight core materials, like honeycomb, while adding only slightly more weight. Because it is still significantly lighter than other traditional options, 5 lb. foam is used extensively in high-strength structural building, aerospace, and design applications.

  • Extremely easy to handle; cut, shape, and thermoform with a heat gun or oven
  • Used to build bulk rapidly; bond individual sheets to provide additional thickness in target areas
  • Insulative and water resistant
  • Compatible with epoxy, polyester, and vinyl ester resins

Many customers experiment with various thicknesses and densities of foam to find the correct balance between part weight and strength. However, each thickness is well suited for a number of traditional applications:

  • ⅜" thick foam offers significant strength and impact resistance to a laminate, and is commonly used for exterior vehicle structures, boat hulls, and bulkheads.
  • ½" thick foam offers the highest possible strength to a composite as a sandwich core; applications include load-bearing structural supports, structural walls, unsupported flooring, and other high strength parts.

DIAB Divinycell H80 5 lb. density sheets measure 32" X 48".

 
2 Lb. Polyurethane Mix and Pour Foam
For Flotation, Sculpting, and Cavity Filling

This 2 lb. density foam comes as a two-part kit, both parts equally mixed. It is a closed-cell system, meaning individual cells of foam trap in air and keep liquids out. As a result, it is most frequently used for flotation applications, delivering 60 pounds of float per cubic foot. It can be used to fill cavities for reinforcement and insulation, and can be shaped or carved , once cured, for use as a plug in mold-making or sculpting.

  • 2 lb. foam expands approximately 30 times its liquid volume before cure, and will fill any shape.
  • Once two parts are mixed, it will begin to react and expand within 45 seconds, and will continue for several minutes.
  • Closed-cell structure does not react with oil or gasoline, and will not absorb water.
  • Laminate directly onto foam using epoxy or polyester resin; it can also be used with urethane pigments (#141, #143, #152), latex paint, and parting wax (#1016) when used in-mold.

Before filling cavities for insulation, flotation or reinforcement, determine how much foam you'll need.

  • First, calculate the volume of your container in cubic feet. For example 1 ft. high x 1 ft. long x 2 ft. deep = 2 total cubic feet.
  • Second, for 2 lb. foam, multiply that total by 2.5. In this case, 2 cubic ft. x 2.5 = 5 lb. of required foam.

This foam is designed to meet USCG Title 33, Chapter 1, Part 183 when mixed properly.

 
6 Lb. Polyurethane Mix and Pour Foam
Excellent Strength to Weight

This 6 lb. density foam comes as a two-part kit, both parts equally mixed. It is a closed-cell system, meaning individual cells of foam trap in air and keep liquids out. Compared to lower density foams, the 6 lb. Mix and Pour Foam offers superior compressive strength (120 psi), so it's ideal for filling cavities that will be might be used to support a heavy load. It is often used to make millwork, floats for wastewater treatment plants, and Coast Guard buoys. Because of its smaller cell structure, it is also frequently used to make detailed plugs or sculptures.

  • 6 lb. foam expands approximately 10 times its liquid volume before cure, and will fill any shape.
  • Once two parts are mixed, it will begin to react and expand within 60 seconds, and will continue for several minutes.
  • Closed-cell structure does not react with oil or gasoline, and will not absorb water.
  • Laminate directly onto foam using epoxy or polyester resin; it can also be used with urethane pigments (#141, #143, #152), latex paint, and parting wax (#1016) when used in-mold.

Before filling cavities for insulation, flotation or reinforcement, determine how much foam you'll need.

  • First, calculate the volume of your container in cubic feet. For example 1 ft. high x 1 ft. long x 2 ft. deep = 2 total cubic feet.
  • Second, for 6 lb. foam, multiply that total by 7.5. In this case, 2 cubic ft. x 7.5 = 15 lb. of required foam.

This foam is designed to meet USCG Title 33, Chapter 1, Part 183 when mixed properly.

 
2 Lb. Polyisocyanurate Foam Sheets
2 lb./ft.3 - Pattern-Making and Moldless Designs 

Our 2 lb./cubic foot Polyisocyanurate Foam Sheets are best suited for moldless pattern-making and for sandwich core applications where insulation is a factor. The properties of this foam are similar to those of our 2 lb. Mix and Pour Foam (#24/25), so it can be easily cut and shaped with a sharp knife or sandpaper.

  • Sheets are rigid and available in a variety of thicknesses.
  • Closed-cell structure resists oil, gasoline, and water absorption.
  • Glue sheets together to form thicker blocks for shaping functional, moldless parts.
  • Store unused foam away from direct sunlight to avoid degradation.
  • Temperature range: -60°F to 300°F

 
6 Lb. Polyisocyanurate Foam Sheets
1" Thick, 6 lb/ft.3 - Pattern-Making and Moldless Designs 

Our 6 lb./cubic foot Polyisocyanurate Foam is a rigid, closed-cell foam used in insulation, sandwich core, and carving applications where strength is key. The properties of this foam are similar to those of our 6 lb. Mix and Pour Foam (#624/625), so it can be easily cut and shaped with a sharp knife or sandpaper, and its density is suited to hold greater details.

  • Glue sheets together to form thicker blocks for shaping functional, moldless parts.
  • Store unused foam away from direct sunlight to avoid degradation.
  • Temperature range: -297°F to 300°F

 
Six Foot Foam Blocks
Ideal for Full Scale Modeling

Polyisocyanurate foam has been a favorite material of pattern builders for years. With this 6 ft. x 4 ft. x 2 ft. block, you can cut, carve, sand, and sculpt nearly any shape without the hassle of gluing numerous sheets together or pouring your own block.

Although this foam can be easily CNC machined, it should not be hot-wired. Professional results can be achieved by using a variety of hand tools to saw, carve, plane, and smooth out your shape.

To use as a plug, build layers of reinforcement and resin directly onto foam to protect and strengthen your shape. Spray with Duratec® Surfacing Primer (#1041), and buff to a perfect shine. A perfect plug allows for a perfect mold, which eventually yields the perfect part.

 

You can place your order on our website or, if you have any questions, call 1.800.838.8984 | 8:00am - 8:00pm EST Mon-Fri.


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Fibre Glast Development Corp.
385 Carr Drive
Brookville, OH 45309
Phone: 800-838-8984
Fax: 937-833-6555
Email: customerservice@fibreglast.com

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