PMI foam core

Lightweight, high-strength material with exceptional mechanical properties and heat resistance.

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PMI foam core: Lightweight, high-strength solutions for aerospace, automotive

Sky’s PMI foam core sheets combine low density, superior mechanical properties, and heat resistance (up to 200°C). This high-performance material is ideal for demanding composite applications in industries such as aerospace, automotive, wind energy, and rail transit, delivering lightweight solutions without compromising structural integrity.

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Why choose Sky for your PMI foam core needs?

Versatile solutions

PMI cores for a wide range of lightweight sandwich applications and manufacturing methods.

Reliable quality

Consistent materials, clear documentation, and expert support when selecting the right material.

Performance-driven

High stiffness-to-weight and good dimensional stability for demanding composite parts.

Choose PMI foam core products

PMI-F foam

High-temperature capable PMI foam core for demanding prepreg/autoclave sandwich structures.

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PMI-TE foam

Cross-linked rigid PMI foam optimized for strong, stiff sandwich structures where medium-temperature capability and balanced properties matter.

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PMI-F

PMI-F is a high-performance PMI foam core widely used for high-temperature composite manufacturing. It is compatible with high-temperature epoxy autoclave curing processes and remains stable under elevated temperatures. When used with carbon fiber prepregs in sandwich structures, it supports strong interfacial bonding and reliable performance.

100% closed-cell structure
Excellent mechanical properties
High-temperature resistance (up to 200°C)
Compressive creep resistance
High machinability
Thermal conductivity: 0.029–0.035 W/(m·K) (density-dependent)

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PMI-TE

PMI-TE is a cross-linked rigid PMI foam with a molecular structure designed for stable performance in medium-temperature environments. It combines high strength-to-weight and high modulus-to-weight performance with high fatigue resistance and low dielectric behavior, making it a strong choice for dynamic-load sandwich structures.

100% closed-cell structure with small, uniform cells
Low resin absorption rate (supports lightweight parts)
Suitable for multiple molding routes, including autoclave
Works with various resin systems
Thermoformable for complex geometries
High fatigue resistance for high dynamic loads
Extremely low thermal expansion coefficient, good dielectric properties, X-ray transparency
Heat resistance up to 160°C
Thermal conductivity: 0.031–0.038 W/(m·K) (density-dependent)

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PMI Foam Core Q&A

What are the benefits of PMI foam core?

PMI foam core combines ultra-low density with exceptional mechanical strength, making it ideal for lightweight yet durable composite structures. It withstands temperatures up to 200 °C, absorbs minimal resin thanks to its fine closed-cell structure, and offers superior impact and fatigue resistance compared to many other core materials. Its compatibility with advanced manufacturing processes such as RTM and vacuum infusion ensures precision and efficiency, while its non-combustible nature enhances safety. With these properties, PMI foam core is a premium choice for demanding industries—from aerospace and automotive to wind energy, rail, sports equipment, and medical devices—where strength, thermal stability, and long-term durability are essential.

What environmental advantages does PMI foam core offer compared to other core materials?

PMI foam core panels provide several environmental benefits that make it a more sustainable choice. Thanks to its low resin uptake, it reduces the use of harmful substances and minimizes production waste during composite manufacturing. Certain PMI types are also recyclable, and with increasingly sustainable production methods, they contribute to the circular economy. In addition, PMI foam does not emit toxic gases during processing or use, lowering both environmental impact and health risks.

In which industries is PMI foam core used?

PMI foam core is a high-performance material widely used in advanced industries such as aerospace, automotive, wind energy, rail transit, sports equipment, and medical devices. Its unique combination of ultra-low density, high strength, thermal stability up to 200 °C, and excellent fatigue resistance makes it ideal for applications where weight reduction, durability, and reliability under demanding conditions are critical. Read more about the applications here.

Do you offer core material finishing services for PMI foam core?

Yes, Sky Composites offers comprehensive finishing services for PVC foam core boards, 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.

How should PMI foam core be stored and handled to maintain its properties?

PMI foam core sheets should be stored in a dry, cool, and well-ventilated area, protected from direct sunlight, heat, and moisture to preserve its mechanical strength and structural stability. Avoid extreme temperature fluctuations, and handle with care to prevent mechanical damage—especially when moving large or thick sheets, where proper lifting equipment is recommended. For transport, ensure stable securing and padded protection to avoid deformation or breakage. Always keep the material in its original sealed packaging to protect it from dust and moisture, and check its condition before processing, particularly after long storage. Following these guidelines helps maintain the foam’s structural integrity and performance over time.

How to choose between PMI-F and PMI-TE?

Choose PMI-F when your priority is higher temperature capability (e.g., higher-temp epoxy/autoclave workflows) and maximum thermal stability. Choose PMI-TE when you need a stiff, fatigue-resistant core for dynamic loads with medium-temperature capability and broad process/resin compatibility.

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