UNION COMPOSITES is a DNV·GL certified international manufacturer and supplier of high-performance structural PVC foam core. Our proprietary StruCell® technology delivers a rigid, closed-cell core material engineered for exceptional mechanical properties, ultra-low resin uptake, and superior compatibility with composite manufacturing processes, including CNC custom machining. We provide industry-leading PVC foam core solutions for demanding applications worldwide.
UNIONStruCell® PVC Foam Core: Engineered for Superior Performance
Unlike standard materials, our structural PVC foam core is specifically formulated to act as the foundational element in composite sandwich structures. The ultra-high closed-cell and microcellular structure ensures minimal resin absorption during vacuum infusion or hand lay-up, significantly reducing overall part weight and production costs without compromising strength.
Applications of Structural PVC Foam Core
Our PVC foam core is the material of choice for engineers and manufacturers across diverse industries where performance, weight, and reliability are non-negotiable.
As a DNV GL-certified core material, our PVC foam offers superior saltwater resistance for marine composites and sandwich panel construction. It is the preferred choice for critical applications including boat hulls, decks, bulkheads, and superstructures in yacht and commercial shipbuilding.
We enable significant weight reduction in vehicle manufacturing through our high-strength PVC foam core, ideal for sandwich panel applications in RV and motorhome walls, truck refrigeration units, and automotive interiors. The material's stability allows for precision CNC custom machining of complex interior components, improving fuel efficiency without compromising structural integrity.
Our fire-retardant PVC foam core meets rigorous aerospace standards for aircraft interior sandwich panels and UAV components. Its exceptional strength-to-weight ratio and compatibility with CNC custom machining make it ideal for creating lightweight, complex structures where safety and precision are critical.
Trusted by global sports brands, our durable PVC foam core provides excellent shock absorption and waterproof properties for high-performance sports equipment. The material is easily shaped through CNC custom machining to create customized cores for surfboards, bicycle helmets, and archery equipment.
Specifically engineered for unmanned aerial vehicles, our PVC foam core provides the perfect balance of rigidity and lightweight properties for drone frames, fuselage structures, and payload mounts. The material excels in CNC custom machining applications, enabling precise fabrication of aerodynamic components and internal structures. Its vibration damping characteristics and electrical insulation properties make it ideal for sandwich panel construction in both commercial and industrial drone platforms.
Microcellular structure maximizes efficiency and reduces laminate weight.
Exceptional Strength-to-Weight Ratio
Provides critical structural integrity while minimizing mass.
Superior Water Resistance
>95% closed-cell content ensures near-zero water uptake (<1.5%), validated by DNV GL certification for marine use.
Excellent Thermal & Chemical Stability
Performs reliably in temperatures from -50°C to +80°C and resists saltwater, acids, and alkalis.
Precision CNC Custom Machining
Our pvc foam cores are manufactured with consistent density and cell structure, allowing for flawless routing, cutting, and milling to tight tolerances.
Why Choose UNION as Your PVC Foam Core Supplier?
Global TOP 3 Manufacturer
We deliver premium quality PVC foam core at a competitive cost, offering significant savings versus EU and US brands.
Unmatched Precision
We guarantee strict thickness tolerances and density control for consistent performance in your manufacturing process.
Technical Expertise & Support
Our engineering team provides expert material selection guidance and application support to optimize your composite designs.
PVC Foam Core Product Range
We engineer our StruCell® PVC foam core in a range of densities to meet specific structural and weight requirements for every project.
Q: What is the difference between UNION-StruCell® PVC foam core and regular PVC foam board? A: UNION-StruCell® PVC foam core is a premium, engineered structural core material, fundamentally different from standard PVC foam boards in composition, performance, and application:
Application & Performance: Our StruCell® core is designed for high-end structural components that require a high strength-to-weight ratio. It provides critical structural support while significantly reducing overall weight, in addition to offering properties like thermal insulation and chemical resistance. In contrast, regular PVC foam board is a general-purpose material with low structural strength and performance.
Manufacturing & Customization: StruCell® is engineered for precision CNC custom machining, allowing it to be fabricated into complex custom-shaped parts, components, and industrial prototypes beyond simple sheets. Standard PVC foam board is typically limited to basic shapes and sheets.
Composition & Quality: Our core material uses a refined formulation to achieve a consistent, microcellular closed-cell structure. Many common PVC foam boards are filled with a high content of calcium carbonate (limestone) to reduce cost, which severely compromises their mechanical properties, durability, and weight.
Use Cases: StruCell® is specified for demanding applications in marine, aerospace, automotive, and wind energy industries. Regular PVC foam board is often used for non-structural purposes like signage, displays, and simple modeling where performance is not critical.
Q: What is PVC foam core primarily used for? A: PVC foam core is a rigid, closed-cell material used as the central structural element in composite sandwich panels. It is bonded with fiberglass or carbon fiber skins to create lightweight, strong, and rigid structures for marine, automotive, wind energy, and aerospace applications.
Q: How does your PVC foam core minimize resin absorption? A: Our StruCell® technology creates an ultra-high closed-cell structure with microcellular pores. This architecture physically limits the space available for resin, drastically reducing uptake during lamination processes like vacuum infusion, which lowers overall part weight and cost.
Q: Do you offer custom surface treatments for the core? A: Yes. We provide a variety of surface treatments to enhance bonding, including plain, perforated, and grooved surfaces. We also offer specialized treatments like scrim reinforcement and can develop custom solutions based on your technical drawings.
Q: What certifications does your PVC foam core hold? A: Our manufacturing facility is ISO 9001 certified, and our marine-grade PVC foam core is certified by DNV GL. We comply with international standards including ASTM and ISO, ensuring global acceptance for critical applications.
Q: What is the difference between PVC foam core and PE foam? A: PVC foam core is rigid, closed-cell, and structurally load-bearing, while PE foam is flexible, open-cell, and unsuitable for structural applications. PVC foam offers better water resistance, thermal stability, and fire retardancy.
Q: Can I get custom-sized PVC foam boards? A: Yes, we provide CNC cutting and custom surface treatments (grooved, perforated, scrim-backed) based on your design specifications.
Q: Do you offer free samples? A: Yes, we offer free A4-sized samples for testing and validation.
Q: What is the typical delivery time? A: Small orders: 5–7 days; full container loads: 15–20 days.
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