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Saertex GmbH & Co. KG’s (Saerbeck, Germany) SAER foam is a structural core material combining ultralight foam (PU/PE/PIR) combined with 3D glass reinforcement. Featuring customizable mechanical properties and very low weight, SAER foam is able to act as a replacement for conventional core materials such as PVC, PET and balsa.

The SAER foam series consists of new standard styles SAER foam 80 and SAER foam 60 as well as the SAERfoam + edition. SAER foam 80 has been developed to improve the handling of structures such as boat hulls, decks and large industrial parts made via infusion. SAERfoam 60, which preserves molds, is more dedicated to resin transfer molding (RTM). The SAER foam + edition includes all non-standard articles and enables customized adaptions— fire protection solutions, for example, are possible by combining this series and Saertex LEO.

exhibits a shear modulus up to four times greater in comparison to PVC and PET, Saertex says, ultimately reducing deflection and enabling thickness reduction. SAER foam is also easy and inexpensive to cut, lowering its material cost compared to PVC, and requires less resin consumption compared to PET. The latter is particularly true due to the sheet’s natural flexibility before being impregnated with resin; the ability to produce large, curved shapes can reduce resin consumption by approximately 1 kg/m². Further, for areas below the waterline, the core will not absorb water, in case of outer skin failure.

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Photo Credit: Saertex

Saertex points to one recent application, which combined SAER form with glass noncrimp fabric (NCF) for 25% weight savings for the bodies of Lamberet’s (Saint-Cyr-sur-Menthon, France) Frigolight refrigerated van concept. Made possible with Segula Technologies (Nanterre, France) and Saertex’s design and technical support, the results are a highly durable composite structure in comparison to heavier traditional components, and optimized looks with an improved surface finish.

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