Thin Sheets of Foam Core Materials – Lightweight Solutions for Aerospace and UAV Applications
Sky Composites’ thin foam core solutions – ultra-light, precise materials for aerospace, UAV, and model aircraft with custom processing and global supply.
PVC foam cores engineered for performance and sustainability
Our associated PVC foam core manufacturer, Marex empowers marine, transportation and industrial applications with innovative, durable and eco-friendly PVC sheets.
Why choose Sky for your PVC foam core needs?
Versatile solutions
Durable, impact-resistant cores for diverse composite applications.
Certified quality
Backed by expertise and ISO9001, GL/DNV certifications.
Sustainable options
Achieve your sustainability goals with our eco-conscious materials.
Choose PVC foam core products
MYcell rigid PVC foam
Rigid foam used as the core of sandwich structures for high performance composite materials.
Flexcell impact load PVC foam
Highly resilient, flexible, and easily thermoformable rigid core foam for sandwich composites. With high capacity to absorb dynamic impact.
HYcell temperature resistant PVC foam
High-temperature resistant foam, suitable for high processing temperature like prepreg.
Flexcell-ECO recycled flexible PVC foam
Rigid ecological foam core for high-resilience sandwich composites, flexible and easily thermoformable.
Ultra-thin PVC foam sheet
Ultra-thin, high-performance PVC foam sheets designed for aerospace, UAV and model aircraft applications.
Brochure
PVC foam core products brochure
Download our latest PVC foam core products brochure.
DNV certified for superior performance in marine, wind and construction
Our PVC core materials from Maricell are DNV certified, ensuring they meet the highest standards of safety, quality, and reliability. This certification guarantees that our PVC cores are suitable for critical applications in industries like marine and wind energy, providing consistent performance and durability you can trust.
MYcell rigid PVC foam
Rigid foam used as the core of sandwich structures for composite materials.
The foam is made of 100% closed polyhedral cell cross-linked PVC, free of chlorofluorocarbons. It is the main core material used in shipbuilding for the construction of yachts, motorboats, catamarans and boats. It is excellently used in high-end sport boats such as canoes and kayaks. It has DNV and ISO9001 certifications.
- Highly resistant
- Lightweight
- Low resin intake
Flexcell impact load PVC foam
Flexcell, the expanded PVC foam for core materials of structures with simpler technical solutions.
Made of cross-linked PVC chlorofluorocarbons free, Flexcell is a material that combines high shear elongation with excellent thermoformability, resulting in a highly performing product: flexible, light, resilient and able to absorb dynamic impacts and withstanding shock loads.
- Highly resilient and resistant to impact
- Superior sheer elongation
- Easily flexible and thermoformable
- Low resin uptake
- Compatible with resins used in the marine/nautical sector
HYcell temperature resistant PVC foam
HYcell is a kind of high-temperature resistant foam, suitable for high processing temperature like prepreg, widely used in aerospace and sports equipment.
Flexcell-ECO recycled flexible PVC foam
Flexcell-ECO, the eco-sustainable expanded PVC foam used as a core of sandwich structures for the nautical sector.
Made of cross-linked PVC chlorofluorocarbons free, Flexcell-ECO is a material that combines high shear elongation with excellent thermoformability, resulting in a highly performing product: flexible, light, resilient and able to absorb dynamic impacts and withstanding shock loads.
- Highly resilient and resistant to impact
- Superior sheer elongation
- Easily flexible and thermoformable
- Low resin uptake
- Compatible with resins used in the marine/nautical sector
- Sustainable
Ultra-thin PVC foam sheet
Ultra-thin, high-performance PVC foam sheets designed for aerospace, UAV and model aircraft applications.
Developed for advanced micro-sandwich constructions, our ultra-thin PVC foam sheets (down to 1.2 mm) deliver the perfect balance of lightweight design and rigidity. These sheets provide dimensional precision and high stiffness-to-weight ratio, making them ideal for demanding aerospace and UAV applications. Custom solutions are available to meet specific engineering requirements.
- Extremely lightweight
- High stiffness-to-weight ratio
- Dimensional precision
- Custom solutions available
PVC Foam Core Q&A
In which industries is PVC foam core used?
Sky Composites’ PVC foam core materials are widely used across industries including marine, wind energy, transportation, automotive, construction, and sports equipment. Their combination of strength, durability, and lightweight performance makes them a versatile choice for demanding applications. Read more about the applications here.
Do you offer core material finishing and processing services for PVC foam core?
Yes, Sky Composites offers comprehensive processing and 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.
What’s the main difference between Flexcell, MYcell and HYcell?
MYcell is a rigid, high-strength core that offers excellent temperature and chemical resistance. Flexcell stands out as a flexible, impact-resistant option with outstanding thermoforming capabilities, while HYcell is specifically engineered for high-temperature applications such as prepreg processing. Thanks to these distinct properties, each type is optimized for different engineering requirements, ensuring the right balance of mechanical performance and thermal resistance for any application.
What are the environmental benefits of using Flexcell-ECO?
Flexcell-ECO combines high performance with sustainability, using recycled, chlorofluorocarbons free PVC to reduce waste, energy use, and carbon footprint—while maintaining the durability and low resin uptake required for demanding applications.
What certifications prove the quality of PVC foam core?
Sky Composites’ PVC foam cores are backed by internationally recognized certifications. DNV certification ensures compliance with the highest safety, quality, and performance standards, making it especially valuable for marine, wind energy, and construction applications. In addition, ISO 9001 certification demonstrates the company’s commitment to rigorous quality management practices throughout manufacturing and supply. Read more about our certifications here.
Which PVC foam core is recommended for high-temperature processing methods?
The HYcell temperature-resistant PVC foam is specifically developed for applications that demand reliable performance under elevated temperatures. It is well-suited to processing methods such as prepreg curing and excels in industries like aerospace and sports equipment, where heat resistance is a critical factor. In contrast, other core materials such as MYcell, Flexcell, and Flexcell-ECO also deliver strong mechanical performance but are generally intended for lower temperature ranges, making them ideal choices for marine, industrial, and transportation applications that do not require specialized high-temperature resistance.
Which PVC foam core is best suited for thermoforming?
The Flexcell impact-load PVC foam is an excellent choice whenever extensive thermoforming is required. Engineered for superior flexibility under heat, it allows complex curves and shapes to be formed without cracking, while its high shear elongation ensures the material can easily accommodate stretching during the process. For projects where sustainability is a priority, the Flexcell-ECO recycled PVC foam delivers the same outstanding thermoforming performance, with the added benefit of being produced from recycled, CFC-free material.
Core material processing & kitting
Improve efficiency, lower your cost, increase quality – boost performance with pre-cut parts. Reduce cost, decrease weight, improve quality – get a competitive edge with the optimal finishing.
Learn moreRelated articles
Kitting, cutting, slicing, perforations – simple guide to core material processing
Simple guide to core material processing—cutting, perforating, kitting, and finishing solutions from Sky Composites for wind, marine and other applications.
Composite Foam Cores for Transportation & Commercial Vehicles: Lightweight Strength for Modern Vehicles
Composite foam cores play a vital role in transportation and commercial vehicle manufacturing by combining lightweight performance with outstanding strength. Sky Composites’ PVC and PET foam cores provide modern solutions for building stronger, lighter, and more sustainable vehicles.
Ready to build stronger solutions together?
Partner with Sky Composites to bring innovative, high-performance materials to your industry. Let’s shape the future, one composite at a time.