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Structural Rigid PVC Foam Core Manufacturer

Rigid PVC Foam Core for Marine & Industrial Applications

DNV·GL Certified - Global Supplier of StruCell®
Ultra-High Closed-Cell & Microcellular Structure for Ultra-Low Resin Absorption

UNION COMPOSITES: International Manufacturer of Structural Rigid PVC Foam Core

UNION COMPOSITES is a leading global cross-linked (polyvinyl chloride) PVC foam core manufacturer and supplier, specializing in high-rigidity StruCell® structural PVC foam core.
As a DNV·GL certified manufacturer, we deliver high-performance closed-cell PVC foam core solutions known for exceptional strength-to-weight ratio, superior water resistance, excellent thermal insulation properties, and outstanding CNC machining compatibility. Featuring an ultra-high closed-cell structure with microcellular pores, our foam significantly reduces resin uptake during lamination, lowering overall composite weight and production cost. Combining remarkable rigidity and toughness, our materials are engineered for demanding applications in the marine, drone, automotive, transportation, and industrial sectors.

Global TOP 3 Manufacturer of Rigid Structural PVC Foam Core | UNION-StruCell®

UNION COMPOSITES Logo - Leading PVC Foam Core Manufacturer Since 2009
StruCell® PVC Foam Core Trademark - Structural Core Material
Precision Foam Sheet Slicing Machine for thin PVC foam core
Precision Thin Sheet Capabilities in PVC Foam Manufacturing
As a leading rigid PVC foam core manufacturer and StruCell® structural PVC foam core supplier, UNION COMPOSITES excels in precision manufacturing with our Foam Slicing Machine. This advanced equipment enables production of ultra-thin PVC foam sheets with exceptional accuracy, serving demanding industries like wind energy, marine, drone, and automotive. Comply with DNV GL standards, ensuring reliable solutions for your projects.
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1mm
Thinnest Nominal Sheet Thickness
±​​​​​​​
0.2mm
Thickness Tolerance Control​​​​​​​
CONTACT UNION COMPOSITES

UNION COMPOSITES Certifications: PVC Foam Core Manufacturer & Supplier Compliance

UNION COMPOSITES INDUSTRY EXPERTISE

PVC FOAM CORE APPLICATIONS

  • MARINE
    MARINE
  • AUTOMOTIVE
    AUTOMOTIVE
  • WIND ENERGY
    WIND ENERGY
  • AVIATION
    AVIATION
  • SPORT
    SPORT
  • DRONE
    DRONE

UNION-StruCell® PVC Foam Core: Lightweight Rigid Structural Foam Core

UNION PVC Foam Core Board P45 - Closed-cell thermal insulation core for refrigerated trucks & LNG carriers

PVC Structural Foam Core P45

UNION P45 PVC foam core delivers superior thermal insulation and moisture resistance, engineered for refrigerated trucks, LNG carriers, and low-temperature industrial equipment.
UNION PVC Foam Sheet P60 - Wind turbine blade core board for wind turbine blades & marine composite structures

PVC Structural Foam Core P60

UNION P60 high-strength PVC foam core excels in wind turbine blade cores, marine composites, and nacelle shells, offering optimal fatigue resistance and lightweight durability.
UNION Marine-grade PVC Foam Core Sheet P80 - Corrosion-resistant board for boat hulls

Structural PVC Foam Core P80

UNION P80 marine-grade PVC foam core provides UV stability and saltwater corrosion resistance, ideal for boat hulls, offshore platforms, and high-performance sports equipment.
UNION High-density PVC Foam Board P100 - Structural core sheet for marine bulkheads

PVC Structural Foam Core P100

UNION P100 rigid PVC foam core is a closed-cell, lightweight solution for marine structural components, ship bulkheads, and heavy-duty industrial applications.
Union Smooth PVC Foam Sheet P130 - Gloss-finish core board for aerospace interiors

Structural PVC Foam Core P130

UNION P130 smooth-finish PVC foam core features a gloss hardened surface, designed for aerospace interiors, automotive panels, and premium architectural cladding.
Union Autoclave PVC Foam Core Board P200 - High-temperature sheet for aviation panels

Rigid PVC Foam Core P200

UNION P200 high-density PVC foam core is autoclave-process compatible, serving advanced composites in aviation, automotive racing, military industry, and industrial tooling.
Union Ultra-dense PVC Foam Sheet P250 - Defense-grade core board for critical systems

Rigid PVC Foam Core P250

UNION P250 ultra-dense PVC foam core offers superior mechanical strength for critical applications in defense, aerospace, military industry, and high-pressure industrial systems.

       CUSTOMIZED TO YOUR REQUIREMENTS

OUR ADVANTAGES

Why Choose StruCell® PVC FOAM CORE by UNION

coreUNION COMPOSITES is a premier PVC Foam Core Board manufacturer and supplier, specializing in pvc foam core solutions for marine composites and automotive industries. 

Cost-Saving Premium Quality

UNION-StruCell® PVC Foam Core delivers TOP 3 global quality at 20-30% lower cost vs EU/US brands.

Structural Performance

Our structural PVC foam core meet ISO 9001 standards for load-bearing applications.

Precision Rigidity

Engineered with rigid stability for automotive and marine vibration resistance.

StruCell® Technology

Exclusive formulations for StruCell® certified pvc foam core.
   CNC cutting, Customized surface treatment, processing according to drawings.
   Accept small batch/trial order, no MOQ
   We can point out customers' potential problems and provide better solutions and products based on the customer's process flow.
WHAT WE DO

UNION COMPOSITES: ONE-STOP Rigid PVC Foam Core Manufacturer & Global Structural PVC Foam Core Supplier

Our ISO-certified factory delivers precision engineered Structural and Rigid PVC Foam Core with industry leading specifications:
✅ ±0.2mm Thickness Tolerance - Essential for marine sandwich panels
✅ 80±3kg/m³ Density Control - Guarantees consistent mechanical performance
✅ 500mm+ High-Density Boards - For heavy-load industrial tooling

Leverage 15+ years of Rigid PVC Foam Core manufacturing expertise to:
• Reduce material costs by 20-30% through optimized sheet utilization
• Accelerate prototyping-to-production cycles with custom CNC cutting
• Comply with DNV GL maritime standards, IAF-accredited certifications, and TÜV SÜD industrial safety protocols.
UNION-StruCell® PVC Foam Core Manufacturer Factory

Can't Find Your Ideal Material? 

Need Application-Specific Solutions?

As a Rigid PVC Foam Core Board manufacturer and supplier, our factory's engineering team delivers custom-grade formulations and CNC machining services to meet unique project demands.

Contact Our Composite Specialists 24/7 For:
✅ Material Selection Guidance
✅ Prototype Development Support
✅ Batch Production Optimization

Get Tailored PVC Foam Core Solutions Within 12 Hours
UNION SERVICES

UNION COMPOSITES: Your Trusted Rigid PVC Foam Core Manufacturer & StruCell® Supplier

Cost-Saving

 Free Material Samples + Technical Consultation (Save 20-30% prototyping costs)
 End-to-end quality tracking from ERP system to delivery notes
24/7 pre-sales & after-sales support with multi-language engineers

Precision Manufacturing

 ±0.2mm thickness tolerance control via CNC cutting technology
 3-stage quality inspection: raw material > in-process > finished goods
Real-time production updates through SAP-integrated client portal
 

Global Logistics Solutions

 Customized palletization (Standard/EPAL/CPA options)
 Full-container load (FCL) & less-than-container load (LCL) services
AEO accredited customs clearance in 30+ countries

UNION COMPOSITES: Trusted by Global Partners

As a leading Rigid PVC Foam Core Board Manufacturer, we've empowered 500+ enterprises across 30 countries with high-performance composite solutions. We have also received high recognition from our customers.​​​​​​​
Read More >
  • USA Customer
  • Malaysia Customer
  • Germany Customer

UNION RIGID PVC STRUCTURAL FOAM CORE FAQs

  • What's the DIFFERENCE between UNION's structural rigid PVC foam core (StruCell®) and standard soft PVC Foam?
    More+
    Standard soft PVC Foam is:
    • Flexible, non-load-bearing material
    • Open-cell or non-foamed structure
    • Higher density (500-1200 kg/m³)
    • Limited temperature range (-10°C to +60°C)
    • Absorbs water, degrades in marine environments
    • Used for seals, hoses, and flexible coverings
    • Processed by injection/extrusion molding
     

    StruCell® structural PVC foam core offers:
    • Rigid, load-bearing capability (up to 6.2MPa)
    • Closed-cell structure (>95%)
    • Ultra-lightweight (45-250 kg/m³)
    • Extreme temperature stability (-200°C to +80°C)
    • Waterproof (<1.5% absorption), DNV GL certified
    • Precision CNC machining capability
    • Ideal for marine/industrial structures
    • Complies with international standards (ISO, ASTM)

     

    For project-specific recommendations, consult our engineers.

  • How does the production of rigid PVC foam core differ from standard soft PVC Foam?
    More+

    The manufacturing processes differ significantly:

     

    Standard Soft PVC Foam Production:

    • Made by extruding PVC resin with plasticizers (30-50% content)
    • No foaming process - results in solid, flexible material
    • Simple air cooling after forming
    • Typically used for seals, hoses and other flexible applications

     

    UNION StruCell® PVC Foam Core Production:

    • Uses cross-linked PVC with controlled chemical blowing agents
    • Precision foaming at 150-200°C creates >95% closed-cell structure
    • Undergoes certified curing under specific temperature/pressure cycles
    • Each batch undergoes DNV GL quality testing
    • CNC machined to ±0.2mm tolerances for marine applications

     

    Key Advantages:
    ✓ Cross-linking creates permanent structural integrity
    ✓ Closed-cell formation ensures waterproof performance
    ✓ Full traceability and certification for marine use

     

    For specific technical details about our manufacturing process, download our Material Guide or contact our engineers.

  • What is your PVC foam core thickness and thickness tolerance?
    More+
    Our PVC foam core regular thickness is from 1mm~70mm, and we also support customized thickness. Thickness tolerance is ±0.2mm.
  • Which surface treatment do you have of PVC foam core?
    More+
    • Plain board; Punched board;
    • One side or two sides grooved board;
    • One side or two sides grooved and punched board;
    • Scrim board; Scrim and punched board;
    • Hyperbolic board; Hyperbolic punching plate...
    • We could also support customized surface treatment.
  • How about your delivery time?
    More+
    We provide fast delivery: small orders: 5-7 days; full container: 15-20 days.
  • How about your MOQ and samples?
    More+
    No MOQ, we could provide A4 free samples.
  • Do you have other relevant materials?
    More+
    Yes, we have all materials for infusion and autoclave process. Like peel ply, vacuum bagging film, flow mesh, infusion tube, spiral tube, sealant tape, vacuum hose, vacuum connector and many others.
  • What is PVC Foam?
    More+
    PVC foam is a lightweight closed-cell polymer material made by foaming polyvinyl chloride (PVC) resin. Its honeycomb-like microstructure (closed-cell rate >95%) combines low weight with high strength. As a leading PVC foam board manufacturer, we produce materials with densities from 45-250kg/m³, widely used in marine sandwich panels and wind turbine blade cores.

    More Details, please refer to our article: 《 What is PVC Foam and Why PVC Foam?》

    Key Features:

    Closed-cell structure prevents water absorption
    Excellent thermal insulation (0.035-0.055 W/m·K)
    Chemical resistance to acids/alkalis
  • What is PVC Foam Core?
    More+
    PVC foam core is a rigid composite core material manufactured through controlled cellular expansion. Similar to "steel reinforcement in concrete," it serves as the structural core when bonded with fiberglass/carbon fiber skins. UNION's DNV GL-certified PVC foam core withstand extreme environments from -200°C to +80°C.

    Technical Specifications:

    Thickness tolerance: ±0.2mm
    Density variation: <3%
    Water absorption: <1.5% (ASTM D2842)
  • Is PVC Foam the Same as PE Foam?
    More+
    Material Comparison:
    ■ Temperature Range: PVC (-50~+80°C) vs PE (-20~+60°C)
    ■ Fire Rating: PVC meets UL94 V-0 vs PE flammable
    ■ Eco-Friendliness: PVC recyclable vs PE microplastics
    ■ Cost: PVC 30-50% higher cost but 3-5x longer lifespan
    Application Guidance:
    Choose PVC foam for marine fireproof bulkheads, while PE foam suits packaging cushioning.
  • Foam Board vs PVC Foam Board?
    More+
    Key Differences:
    Strength: Standard EPS foam <1MPa vs PVC foam up to 25MPa+
    Weather Resistance: PVC UV-stable vs regular foam crumbles outdoors
    Machining: PVC allows CNC precision vs basic cutting for regular foam
OUR BLOGS

LATEST NEWS ARTICLES

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PVC Foam Board (Sunboard) vs PVC Foam Core: What's the Difference?

PVC foam board (Sunboard, Celuka board) and structural PVC foam core share the same polymer and closed-cell look, but they are made by different processes and are not interchangeable. This guide compares extruded advertising-grade board with moulded, cross-linked structural core on process, density, strength, heat resistance, water absorption and resin compatibility, and explains which applications each one suits. It also lists the StruCell structural PVC foam core grades from 48 to 300 kg/m3 with sheet sizes, thicknesses and surface options.

11 September 2026
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What is the difference between structural PVC foam core and standard PVC foam board

When you design load-bearing composite panels, you need a high-strength, cross-linked PVC foam core. This closed-cell material effortlessly handles heavy shear, bending, and compression forces. Conversely, you use standard PVC foam board—an un-cross-linked, heavily filled plastic sheet—strictly for

31 July 2026
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Why the Composite Sandwich Panel Structure is the Ultimate Lightweight Engineering Solution

Discover the engineering mechanics behind the composite sandwich panel structure. Learn how separating high-strength outer skins with a lightweight PVC foam core maximizes bending stiffness and delivers an exceptional strength-to-weight ratio for marine, wind energy, and industrial applications without compromising structural stability.

22 July 2026
UNION is committed to providing customers with one-stop composite solutions.

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  +86-18261198591
   WhatsApp/Wechat: +86-18261198591
    East Taihu Rd., No. 120, Changzhou City, Jiangsu Province, China

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