There are several foam core materials on the market today that are capable of being thermo-formed into relatively complex shapes. Two of the market leaders are Rohacell and Airex.
Whilst these foams are quite different they both have the same basic characteristic in that when heated to a set temperature they are capable of being formed and upon cooling will keep that form.
Airex can be formed at quite low temperature (about 100 deg C) where as Rohacell requires a higher temperature (180 - 200 deg C) but has the advantage that it can be autoclaved at 120 deg C as part of a conventional co-cure operation
As specialists in this field we have developed a range of bespoke thermo-forming machines and experience to manufacture deep drawn and simple curved parts.
The use of pre-formed core materials has enabled several of our customers to use these superior core materials in their designs.
For further information of this manufacturing process please contact us.
To help you understand the benefits of thermoforming better we have put together a short video showing the process.
One of our thermoforming machines.
Aviation