Sandwich Core Materials

FLEXOKORE BALSA CORE MATERIAL
Probably the best known core material available to the GRP moulder, Balsa wood has been widely accepted and used for many years in the construction of GRP boats and large commercial mouldings.
Flexokore is produced from small rectangles of end grain Balsa with a glassfibre scrim backing that retains the panels integrity while allowing sufficient flexibility to conform to compound curves.
Flexokore has been approved by Lloyds Register of Shipping and Det Norske Veritas for use in the construction of yachts and small craft.
Flexokore is supplied in 2' x 4' panels with thickness of 1/4",3/8", 1/2”, 5/8",3/4"and1".

POLWRETHANE FOAM RESIN
Supplied as a two-part pack, a resin and a foaming agent are weighed out in the proportions of 1:1.16 by weight, or 1:1 by volume, part A requires pre-mixing prior to mixing with part B, which when mixed will expand and create a tough but light foam with a density of approximately 32kg/M³ Mixing requires approximately 1 minute, pouring a further 1/2-1 minute and after a total of approximately 5 minutes the foam is fully hardened. It is poured into cavities for insulation and buoyancy purposes although it is not suitable for vessels made to Lloyds standards. Two of its more interesting uses are filling bodywork cavities between boot and driver compartments on saloon racing cars and manufacturing personalised racing car seats. (See instructionson our products pages). 2kgs of liquid mixture @ 20°C will produce approximately 0.33M³(2.2'³).

POLYURETHANE FOAM SHEET
A closed cell foam compatible with polyester resins. For buoyancy, and forming light-weight stiffening ribs in GRP mouldings. One cubic foot of polyurethane
foam sheet will provide at least 60lbs (27kgs) of positive buoyancy. Stock thickness 1/2” (12mm), 3/4" (19mm), 1" (25mm), 2" (50mm), 3" (75mm) and 4" (100mm) in sheets 4' x 3' (1219mm x 914mm), nominal density 2lb (900grms) cu. ft. Other sizes available.

SCORE BOARD
This is a rigid urethane foam which has narrow slots cut part way through on both sides of the sheet, to enable it to conform, to a compound radius making it easy to fabricate sandwich construction.
During the laminating the slots become filled with resin, resulting in a solid construction.
Available in sheets 2' x 2' and in thicknesses of 1/2" upwards.
Order ref. AAO 17160

POLYCORE
Polycore is a high strength, low weight Core Material constructed from a non-woven continuous polyester fibre fabric encapsulating microballoons.
Polycore is used as a core material and anti-print layer in the production of GRP mouldings such as boats, building panels, tanks, automotive parts etc.
Polycore reduces resin usage in laminates due to the micro-balloon technology.
 

For Example:
1 mm chopped strand mat laminate, 450gm/m2 csm + 1050gm/m2 resin = 1500gm.
1 mm Polycore laminate, 60gm/m2Polycore + 650gm/m2 resin = 710gm.
 

  • Polycore can offer a weight saving of over 50%.
  • Polycore reduces exotherm and shrinkage.
  • Polycore provides excellent anti-print through properties, avoiding woven           roving pattern in gel coats and preventing the print-through of ribs and                 inserts.
  • Polycore offers consistent laminate thickness.
  • Polycore can be used as a bedding layer for balsa or foam.