Engineered Foams

About Engineered Foams

Engineered foams are lightweight polymer materials designed to provide application-specific properties such as structural support, thermal and acoustic insulation, sealing, cushioning, and temperature resistance. They are used in demanding aerospace, defense, transportation, electronics, and industrial applications where reducing weight without sacrificing performance is critical.

Curbell offers engineered foam materials including polyimide foam, rigid polyurethane foam, polyethylene foam, PVDF foam, and polypropylene foam, with performance characteristics ranging from high-temperature capability and dimensional stability to flame resistance, low water absorption, dielectric properties, and high strength-to-weight ratios. Material options include foams for structural cores, aircraft interiors, radomes and antennas, seals and insulation, thermoformed components, and other applications where conventional foam materials may not provide the required level of performance.

Length, width, thickness, and diameter tolerances vary by size, by manufacturer, brand, and grade.

Engineered Foam Properties and Material Options

Polyimide Foam

DuPont™ Vespel® SF Polyimide Foam– DuPont™ Vespel® SF is a high-performance, open-cell polyimide foam for demanding aerospace applications requiring high-temperature resistance, low weight, thermal and acoustic insulation, dampening, and sealing. Offering continuous use at 300°C (572°F) and customizable densities of approximately 10 – 35 lb/ft³, it can be formed or machined into complex geometries and is well suited for abradable and stator vane seals, nacelle insulation, bushing packing, and reinforced composite panels. View the DuPont™ Vespel® SF data sheet for typical properties.

Rigid Polyurethane Foam

LAST-A-FOAM® RF-2200 Dielectric Low-Density Foam Series (3–6 lbs/ft³) – Low-density, closed-cell polyurethane foam for RF-transparent radomes, antennas, and other dielectric applications requiring minimal signal interference. RF-2200 has a low dielectric constant, excellent dimensional stability, high-temperature performance up to 350°F (177°C), and low water absorption for aerospace, defense, and electronics applications.

LAST-A-FOAM® FR-3700 Performance Core Series (3–25 lbs/ft³)– Closed-cell, flame-retardant polyurethane foam offering high strength-to-weight ratio, low water absorption, and clean machinability. Used in aerospace interiors, structural components, tooling, and industrial applications requiring lightweight performance and flame resistance.

LAST-A-FOAM® FR-3800 FST Performance Core Series (3–40 lbs/ft³) – Fire, smoke, and toxicity-compliant polyurethane foam core meeting stringent aerospace requirements, used for aircraft interior panels, bulkheads, and other safety-critical applications.

Polyethylene Foam

Plastazote® HD115– Plastazote® HD115 is a lightweight, crosslinked polyethylene block foam designed for durable applications across a range of industries. With a nominal density of 115 kg/m³ (7.2 lb/ft³) and a recommended maximum operating temperature of 125°C (257°F), it offers high tensile and tear strength, low water absorption, and a firm Shore OO hardness of 95.

PVDF Foam 

Zotek® F OSU XR 120– Zotek® F OSU XR 120 is a high-performance, closed-cell PVDF foam supplied in sheet form that can be thermoformed into simple or complex shapes. With a density range of 97 – 131 kg/m³ (6 – 8.2 lb/ft³) and a recommended maximum operating temperature of 155°C (310°F), it is a strong candidate for applications requiring lightweight construction, thermal insulation, and stringent heat release, smoke, toxic gas emission, and flammability performance.

Zotek® F OSU XR 150– Zotek® F OSU XR 150 is a high-performance, closed-cell PVDF foam supplied in sheet form and capable of being thermoformed into simple or complex shapes. With a density of 140 kg/m³ (8.75 lb/ft³) and a recommended maximum operating temperature of 155°C (310°F), it combines greater tensile strength and compression resistance with thermal insulation and stringent heat release, smoke, toxic gas emission, and flammability performance.

Polypropylene Foam

Foamlite® P (Closed Cell Polypropylene Foam Sheet)– Foamlite® P is a lightweight, UV stable sheet with solid polypropylene surfaces and a polypropylene foam core. The material is 28% lighter than solid PP sheet. Foamlite® P is stiffer than either polyethylene foam or PVC foam sheet materials. It is often specified for applications such as vehicle cabinets and shelving and animal trailer wall cladding where light weight and high stiffness are required.