THE CAMX FORECAST

Published 07/25/2025

Foamed plastics are well suited for CFRP core applications

CAMX 2025: Sekisui Kasei USA presents ST-Eleveat RNW E foamed plastic and ST-Foamac rigid foam board products designed to support composite core needs.

Edited by: Grace Stubbins

Senior Managing Editor, CompositesWorld and Products Finishing

Source | Sekisui Kasei USA

Sekisui Kasei USA (Mountain Pleasant, Tenn., U.S.), a subsidiary of Sekisui Kasei Co. Ltd., is presenting some of its finished foam products including ST-Eleveat RNW E and ST-Foamac. Sekisui Kasei develops and manufactures core materials specifically designed for carbon fiber-reinforced polymer (CFRP) applications. Its operations span the U.S., Japan and Europe, actively engaged in advancing its materials on a global scale.

ST-Eleveat RNW E foamed plastic is made from PET resin and is available in two forms: beads type (contains 30% recycled content) and sheet type (contains 75% recycled content). This product can be molded into the desired shape using tooling, similar to EPS products. Sekisui Kasei explains that this reduces machining processes and enables the company to mass produce the materials for CFRP applications as a core material.

ST-Eleveat RNW E is environmentally friendly, heat-resistant and 80-90% lighter compared to nonfoamed plastic molded products. It is available in densities 150-300 g/L, with low-density grades currently under development. Bead size ranges from 2.3-2.7 mm. Applications include automotive and transportation, aircraft, marine, electronic devices and CFRP/GFRP foam core sandwich structures.

ST-Foamac is a white rigid foam board made by foaming rigid acrylic resin. It can be used as composite core for buildings and construction, panels, vessels/vehicles and more. This range of applications has also been extended to CFRP core materials.

ST-Foamac is available in two grades depending on heat-resistance needs — S grade at 115℃ (239℉) and HR grade at 180℃ (338℉). Compared to rigid foams of the same density, the material has a higher resistance to tension, bending and compression. It also has good workability. Grades include S #1000 (110 kg/m³), S #1500 (80 kg/m³), S #2000 (56 kg/m³) and HR #1000 (110 kg/m³).

Sekisui Kasei’s mission is to go beyond simply meeting customer requirements. Its team works closely with partners to tailor material solutions that address both performance and processing needs.