Our Clients
Description
This professional flexible foam core material is a high-performance polyester fleece designed specifically for resin infusion and vacuum processes. Engineered to combine low resin uptake with excellent mechanical performance, it offers a cost-effective way to build lightweight, strong composite laminates.
Supple yet robust, this polyester fleece core conforms easily to complex shapes, making it ideal for use in marine, automotive, architectural and industrial composite structures. Available in a choice of sheet lengths and thicknesses, it helps reduce overall laminate weight and resin consumption while maintaining high strength and dimensional stability.
Product Features
- High-performance polyester fleece foam core optimised for resin infusion and vacuum processes.
- Available sheet lengths of 1000, 2000, 3000, 4000 and 5000 mm, with additional lengths available to suit project requirements.
- Standard sheet width of 1200 mm for efficient nesting and panel layout.
- Choice of 2 mm and 3 mm thicknesses to balance weight, stiffness and flexibility.
- Flexible construction that drapes and conforms to curved or complex mould geometries.
- Low resin uptake structure designed to minimise resin usage and laminate weight.
- Consistent density and structure for repeatable performance across multiple panels.
Key Features and Benefits
- Reduces resin consumption, helping lower material costs and laminate weight without compromising strength.
- Flexible fleece structure makes lay-up quicker and easier over tight radii, contours and compound curves.
- Improves stiffness and impact performance of composite parts by adding a lightweight core layer.
- Supports efficient resin flow during infusion, promoting even wet-out and reducing the risk of dry spots.
- Supplied in practical sheet formats, simplifying handling, cutting and fitting on the shop floor.
- Suitable for a wide range of composite systems, allowing use across multiple projects and applications.
Specifications
| Specification | Detail |
|---|---|
| Material | Polyester fleece flexible foam core |
| Sheet length options | 1000, 2000, 3000, 4000, 5000 mm (plus additional lengths available) |
| Sheet width | 1200 mm |
| Available thicknesses | 2 mm and 3 mm |
| Processing methods | Suitable for resin infusion, vacuum bagging and other closed-mould processes |
| Typical applications | Lightweight structural cores in marine, automotive, architectural and industrial composites |
Applications and Ideal Uses
This flexible polyester fleece core is suitable for a broad range of composite manufacturing projects where weight reduction, strength and efficient resin use are priorities.
- Marine panels, decks, bulkheads and interior structures in boats and watercraft.
- Automotive body panels, fairings and interior composite components.
- Architectural cladding, façade elements and decorative composite panels.
- Industrial covers, housings and equipment panels requiring lightweight rigidity.
- Sports and leisure composite products such as boards, shells and enclosures.
Frequently Asked Questions
Can this polyester fleece core be used with different resin systems?
Yes, the polyester fleece core is compatible with most common composite resin systems used in infusion and vacuum processes, including polyester, vinyl ester and epoxy resins. Always carry out a small trial if you are using a new resin system or process setup.
How do I cut and shape the foam core sheets for complex moulds?
The sheets can be easily cut using sharp knives, scissors or suitable cutting tools. The flexible fleece construction allows the material to drape over curves and contours; for very tight radii, you can trim smaller sections and overlap or butt-join them within the laminate.
Does the low resin uptake affect the strength of the finished laminate?
No, the low resin uptake is designed to reduce excess resin in the core while still allowing full wet-out and bonding to the surrounding laminate. This results in a lighter panel without compromising structural performance when used correctly within a properly engineered laminate design.