FOAMING MATERIALS FOR
COMPOSITE MANUFACTURING
WHAT IS INSITUCORE®
INTERNAL PRESSURE
ENABLES NET SHAPES
L&L InsituCore® Foaming Core Technology is a family of one-component, heat-activated foaming materials that can be used to create composites with foam core. Placed in a heated tool, the material foams to fill the mold cavity and form net-shape parts without time-consuming machining processes or energy-intensive autoclave operations.
- Simplified production process that results in a final lightweight net-shape part or preform with targeted density and strength
- Reduced layup time, cycle time, and labor cost compared to traditional processes
- Reduced waste from machining operations
- Forms and bonds so additional adhesive layers are not required
- Reduced number of reinforcement layers for weight reduction
FEATURES FOR HIGH PERFORMANCE
With InsituCore®, internally generated pressure is used to create net shape, 3D parts that are both lightweight and strong in a simple, clean process. Compared to traditional manufacturing and machining methods, these materials enable faster cycle times, a reduction in waste material, and optimized production processes by eliminating secondary machining and assembly operations.
High Strength
- High compressive strength
- High stiffness-to-weight ratio with a wide range of volumetric expansion
Process
Optimization
- Enables fast cycle times
- Minimal waste, low capital investment, small manufacturing footprint
- Requires no liquid resin infusion
Flexibility in
Design
- Good acoustic & thermal insulation
- Fire-resistant products possible
- Enables lightweighting
Safe and Easy
Handling
- No isocyanates
- Alternative to polyurethane foams
*Always follow SDS guidelines for safe handling.
A JOURNEY FROM RAW MATERIAL
TO A REFINED SHAPE
The InsituCore® process redefines efficiency and precision in composites production. Simply place the InsituCore® material into the cavity mold along with the reinforcement fiber layers, then close and heat the mold. As the material foams, it builds pressure to completely fill the cavity. Once cooled, the mold can be opened to reveal a refined structural foam part—ready for use. This streamlined approach transforms raw materials into high-quality components with ease and reliability.
Material Formats
- Expands to produce a rigid, cross-linked foam
- As a result of the compressive and flexural strength, the number of reinforcement layers may be reduced
Thermosetting
- Expands to produce a viscoelastic foam
- Can provide a damping effect in the finished part
- Excellent adhesion to low surface energy substrates
Thermoplastic
Thermosetting
EXPLORING POSSIBLE USES
LEARN MORE ABOUT INSITUCORE®
Download our resources to find out more about our InsituCore® foaming materials.
Follow the InsituCore® LinkedIn page for technology updates and recent applications.
EVENTS
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