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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

Our #1024 Divinymat was engineered specifically for vacuum infusion. Featuring grooves, perforations, and cross scoring, this core material creates flow channels for resin while adding strength. Divinymat is a 3.8lb DIAB Divinycell® H with cross scoring and offers the highest structural properties of any available flow media. Bonded to a light scrim cloth, this core will conform to most simple curves and shapes. Sold by the sheet, each sheet measures 1/8" thick x 32" x 48".  
Vinyl Foam: Divinycell 3 lb. Density
Light Weight Versatile Foam

DIAB® closed cell vinyl foams are an excellent core material with superior mechanical properties. When used as a structural sandwich core, these foams provide ultra-low weight, improved stiffness and impact resistance, and they offer insulative properties. At 3lb/cuft, the density of these foams is similar to that of some honeycombs, though strength properties are not as high as costlier honeycombs. The low density allows our 3# vinyl foams to be used extensively in weight-sensitive aircraft and automotive applications. Vinyl foams are extremely easy to cut and shape, individual sheets can be bonded to provide additional thickness in specific areas, and they can be used to build laminate bulk rapidly.

The different thicknesses we offer are tailored to different applications. 1/8" thick foam is best used for laminates that require only additional impact resistance or parts with a small cross-section. If you want to make reinforced vertical components or walls, 3/8" thick foam offers additional strength and impact resistance without adding significant weight. 1/2" thick foam offers the highest strength to a composite part. Applications for 1/2" vinyl foam include structural flooring, exterior paneling, and other structural components.

Vinyl Foams are compatible with all of our resins and can be easily thermoformed with a heat gun or oven. DIAB® Divinycell H45 3 Lb. Density, 32" X 48" Sheets.  
Vinyl Foam: Divinycell 4 lb. Density
Balanced Weight and Strength

Due to their outstanding structural properties, DIAB® closed cell vinyl foams are an excellent choice for sandwich core material in a composite part. When used as a structural sandwich core, 4lb vinyl foams strike a balance between strength and weight, while offering insulative properties. Vinyl foam sandwich cores significantly reduce weight and increase stiffness while maintaining or increasing strength compared to a thick reinforced laminate. 4lb foam is used extensively in marine (leisure, military and commercial) and automotive applications.

Applications vary for the different thicknesses we offer. Commonly used for vertical supports and walls, 3/8" thick foam offers additional strength and impact resistance to a composite laminate without adding significant weight. 1/2" thick foam offers significant strength to a part with a limited impact on overall weight. Applications for 1/2" vinyl foam include boat hulls, exterior panels, and other structural components. Many customers experiment with various thicknesses and densities of foam to find the correct balance between part weight and strength.

Vinyl Foams are compatible with all of our resins and can be easily thermoformed with a heat gun or oven. DIAB® Divinycell H60 4 Lb. Density, 32" X 48" Sheets.  
Vinyl Foam: Divinycell 5 lb. Density
Highest Strength Foam

Looking to make a strong composite part? DIAB® closed cell vinyl foam is an excellent choice. 5lb vinyl foams add significant strength to a laminate when used as a sandwich core. With compressive strengths over 200psi, these foams offer more strength to a laminate than light weight honeycombs with only a minor weight penalty. This allows them to be used extensively in applications where ultimate laminate strength is of the utmost importance. Still significantly lighter weight than a traditional composite lamination, 5lb foams are used extensively in high strength structural building, aerospace, and design applications.

Offering significant strength and impact resistance to a laminate, 3/8" thick foam is commonly used for exterior vehicle structures, boat hulls, and bulkheads. 1/2" thick foam offers the highest strength to a composite part possible. Applications for 1/2" vinyl foam include load bearing structural supports, structural walls, unsupported flooring, and other high strength parts.

Vinyl Foams are compatible with all of our resins and can be easily thermoformed with a heat gun or oven. DIAB® Divinycell H80 5 Lb. Density.

1495 & 1496 are 32" X 48" Sheets.  
2 Lb. Polyurethane Mix and Pour Foam
For Flotation, Sculpting, and Cavity Filling

Our #24/25 is a two-part, equal mix, self-rising, 2lb/ cu. ft. density closed-cell foam system. Foaming begins within 45 seconds after the two liquids are mixed and continues for several more minutes. The foam expands approximately 30 times its liquid volume before curing, and will fill any shape cavity. It does not react with oil or gasoline and it will not absorb water. #24/25 is ideal for flotation applications and provides 60 pounds of flotation per cubic foot of foam. Unlike polyester foams, polyurethane foam is compatible with both polyester and epoxy resins. This foam is designed to meet USCG Title 33, Chapter 1, Part 183 when mixed properly.

When filling cavities for purposes of insulation, flotation or reinforcement; estimate the volume of the cavity and multiply the volume (in cubic feet) by 2.5 to determine the number of pounds of foam to mix.

For instance if you wish to fill a cavity measuring 1ft. by 1ft. by 2ft., the cavity has a volume of 2 cubic feet. Multiplying that volume by 2.5 indicates you need 5 pounds of foam mix (2.4 lb. #24 and 2.6 lb. #25). 
6 Lb. Polyurethane Mix and Pour Foam
Excellent Strength to Weight

Our #624/625 is a two-part, equal mix, self-rising, 6lb/cu. ft. density closed-cell foam system. When compared to lower density foams, 6# Mix and Pour Foam can be used to make significantly more detailed plugs and sculptures due to its higher density and smaller cell structure. It can also be used to make millwork, WWTP floats or coast guard buoys. Foaming begins within 60 seconds after the two liquids are mixed and continues for several more minutes. The foam expands approximately 10 times its liquid volume before curing, and will fill any shape cavity. It does not react with oil or gasoline and it will not absorb water. With a compressive strength of 120psi, #624/625 is ideal for structural void filling applications. Unlike polyester foams, polyurethane foam is compatible with both polyester and epoxy resins. Polyurethane foam can be pigmented using urethane pigments, and is paintable using standard latex based paints.

When filling cavities for purposes of insulation, flotation or reinforcement; estimate the volume of the cavity and multiply the volume (in cubic feet) by 7.5 to determine the number of pounds of foam to mix. For instance if you wish to fill a cavity measuring 1ft. by 1ft. by 2ft., the cavity has a volume of 2 cubic feet. Multiplying that volume by 7.5 indicates you need 15 pounds of foam mix (7.2 lb. #624 and 7.8 lb. #625).
When properly mixed, this foam is designed to meet USCG Title 33, Chapter 1, Part 183.  
2 Lb. Polyisocyanurate Foam Sheets
2 lb./ft.3. Pattern-Making and Moldless Designs 

Our 2 lb./ft.3 polyisocyanurate foam sheets are rigid, closed cell and are available in varying thickness. They are suitable for most sandwich core applications and are ideal for those which require insulating cores. The properties for these foams are similar to our #24/25 2lb Mix and Pour foam. These foams are easily cut and shaped with a sharp knife and sandpaper. Pattern-making has never been quicker! You can also glue together several sheets form blocks as thick as necessary for shaping functional moldless-type parts.  
6 Lb. Polyisocyanurate Foam Sheets
1" Thick, 6 lb/ft.3. Pattern-Making and Moldless Designs 

This polyisocyanurate foam is a rigid, closed cell foam used in insulation, core material and carving applications where strength is important. With similar properties to our 624/625 6lb Mix and Pour foam, you can easily cut and shape with a sharp knife and sandpaper. Pattern-making has never been quicker! You can also glue together several sheets from blocks as thick as necessary for shaping functional moldless-type parts.  
Six Foot Foam Blocks
Ideal for Full Scale Modeling

Polyisocyanurate foam has been a favorite material of pattern builders for years. With this 6' long, 4' wide, 2' thick block, you can cut, carve, sand, and sculpt any shape imaginable 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 when working by hand. With the variety of tools available on our site, you can saw, carve, plane and smooth out your shape. You can then lay layers of fiberglass and resin to protect and strengthen your shape. Finally, spray Duratec® Surfacing Primer and buff to a perfect shine. A perfect plug allows for a perfect mold which makes the high gloss, perfect part you want.  

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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