PET foam core

PET (polyethylene terephthalate) foam core is a versatile, 100% recyclable material with excellent shear and compressive strength. It is highly resistant to water penetration, has minimal resin absorption, low thermal conductivity and handles temperatures up to 150°C with no outgassing or expansion.

At Sky Composites, PET foam core is available in densities ranging from 60 to 200 kg/m³, allowing engineers to choose the optimal balance between weight and strength for their specific application. Lower densities are ideal where lightweight performance is a priority, while higher densities deliver greater strength and compressive resistance. Across the full range, the material ensures minimal water ingress and resin uptake, with stable and consistent quality.

Sky Composites’ PET foam core is widely applied across industries such as rail transportation, construction, wind energy, marine, and general industrial use. Its lightweight yet durable properties, combined with excellent strength, fatigue resistance, thermal stability, and moisture protection, make it a reliable and sustainable choice for demanding applications. Read more about the applications here.

The thermal conductivity of PET foam core is very low which gives it excellent insulation properties for energy-efficient applications. Sky Composites’ PET foam core achieves values down to 25 mW/m·K, ensuring strong thermal stability and insulation performance at high temperatures without outgassing or expansion. These properties make it highly effective for improving thermal management in composite structures across construction, transportation, and wind energy industries.

PET foam core stands out for its strong environmental benefits. Made from post-industrial recycled PET, it is fully recyclable at the end of its life, supporting the circular economy while significantly reducing carbon footprint. Its production diverts millions of plastic bottles from landfills and oceans, avoids toxic gas emissions, and increasingly relies on sustainable processes such as CO₂ foaming. With long durability and extended service life, PET foam combines high performance with clear sustainability advantages, making it a responsible alternative to traditional core materials.

Yes, Sky Composites offers comprehensive finishing services for PVC foam core materials, including a wide range of cutting and machining options such as scrim, scoring, perforation, grooves, slits, and infusion cuts. These finishes improve formability, resin flow, and overall component performance, while tailored kitting services provide pre-cut, labeled core kits that streamline production and minimize waste. You can read more about it here.