Rohacell Foam Core Fiberglass Panels Advance Lightweight Design
October 2, 2025
Imagine your race car needing a lighter body to gain a competitive edge on the track, or your drone requiring a sturdier structure to withstand the pressures of high-altitude flight. In the pursuit of lightweight yet high-strength materials, composites play a pivotal role. Among these, fiberglass sandwich panels with Rohacell foam cores are increasingly favored by engineers and designers for their unique structural advantages. This article explores the properties of these high-performance materials and provides a comprehensive purchasing guide.
Fiberglass sandwich panels are composite materials typically consisting of two thin, rigid fiberglass skins bonded to a lightweight core material. This design ingeniously combines the high strength of fiberglass with the weight-saving properties of the core, achieving an exceptional strength-to-weight ratio. The fiberglass skins provide superior tensile and flexural strength, while the core material supports and distributes loads, preventing buckling or deformation.
Among various core materials, Rohacell foam stands out for its exceptional properties. This closed-cell, high-performance structural foam offers several significant advantages:
- Extremely low density: Rohacell's minimal weight significantly reduces the overall mass of composite structures while maintaining integrity.
- Excellent strength and stiffness: Despite its lightness, Rohacell provides outstanding compressive strength and rigidity to support fiberglass skins.
- Superior thermal stability: The material maintains structural integrity and performance at elevated temperatures.
- Exceptional creep resistance: Rohacell retains its original shape and dimensions even under prolonged loading.
- Ease of fabrication: The foam can be easily cut, shaped, and bonded for various manufacturing processes.
Available in two thickness variations (0.118-inch and 0.25-inch), both utilizing 0.030-inch thick fiberglass skins, these panels serve diverse industrial needs:
| Product Code | Dimensions | Price |
|---|---|---|
| G5129 | 5.75" × 5.75" | $22.45 |
| G5128 | 5.75" × 11.75" | $40.20 |
| G5127 | 11.75" × 11.75" | $71.85 |
| G5126 | 11.75" × 23.75" | $138.40 |
| G5125 | 12" × 48" | $252.60 |
| Product Code | Dimensions | Price |
|---|---|---|
| G5259 | 5.75" × 5.75" | $20.75 |
| G5258 | 5.75" × 11.75" | $37.20 |
| G5257 | 11.75" × 11.75" | $68.50 |
| G5256 | 11.75" × 23.75" | $128.15 |
| G5255 | 12" × 48" | $233.85 |
These composite panels are particularly suited for:
- Lightweight structural components: Ideal for aerospace, automotive, and marine applications where weight reduction enhances performance.
- Traditional material replacement: Effective substitutes for metals and woods, offering superior strength-to-weight ratios.
When selecting Rohacell-cored fiberglass panels, consider these critical factors:
- Application requirements: Identify specific performance needs such as load capacity or thermal resistance.
- Dimensional specifications: Choose appropriate sizes and shapes for your project requirements.
- Budget considerations: Balance performance needs with cost constraints.
- Supplier reliability: Partner with reputable manufacturers to ensure material quality and consistency.
Real-world implementations demonstrate the material's versatility:
- Motorsports: Race car bodies utilize these composites for weight reduction and aerodynamic efficiency.
- Unmanned aerial vehicles: The panels provide structural integrity while minimizing weight for extended flight durations.
- Marine engineering: Ships benefit from the material's strength, durability, and insulation properties.
Rohacell foam-cored fiberglass panels represent a significant advancement in composite technology, offering engineers an optimal solution for lightweight, high-strength applications across multiple industries.