PVC Foam Core vs PET Foam vs SAN Foam: Which One Should You Choose?

1. Overview of Foam Core Materials

Foam cores are widely used in sandwich composites to provide lightweight stiffness, shear strength, and fatigue resistance. Typical applications include:

Boat and yacht construction

Wind turbine blades

Transportation panels

Industrial and construction sandwich structures

Among available materials, PVC, PET, and SAN foams dominate the global composite market.

2. PVC Foam Core

Key Characteristics

Closed-cell structure

Excellent shear and compression properties

Good fatigue resistance

Compatible with vacuum infusion, RTM, and hand lay-up

Advantages

Proven performance in marine and wind energy applications

Wide density range (typically 40–250 kg/m³)

Easy to thermoform and contour

Low water absorption

Limitations

Higher cost than PET foam in some regions

Moderate temperature resistance compared to SAN

Typical Applications

Boat hulls and decks

Yacht superstructures

Wind turbine blades

High-performance sandwich panels

Example Use Cases

3. PET Foam Core

Key Characteristics

Thermoplastic foam made from PET

Good impact resistance

Higher recyclability

Advantages

Lower material cost

Environmentally friendly (often made from recycled PET)

Good thermal resistance

Limitations

Higher density for the same stiffness compared to PVC

More difficult to contour for complex shapes

Lower fatigue performance in dynamic loading conditions

Typical Applications

Transportation panels

Rail and truck interiors

Construction sandwich panels

Example Use Cases

4. SAN Foam Core

Key Characteristics

Based on Styrene Acrylonitrile polymer

High temperature resistance

Excellent fatigue and creep performance

Advantages

Superior performance under cyclic loading

Better heat resistance than PVC and PET

Good resin compatibility

Limitations

Higher material cost

More limited global supply

Less flexible in processing compared to PVC

Typical Applications

High-end wind turbine blades

Aerospace and advanced industrial structures

Example Use Cases

5. Comparison Table

Property	PVC Foam	PET Foam	SAN Foam
Density Range (kg/m³)	40–250	60–200	60–220
Compressive Strength (MPa)	1.5–5	1–4	2–5
Shear Strength (MPa)	0.8–3	0.6–2.5	1–3.5
Water Absorption (%)	<1	2	1
Thermal Resistance (°C)	70	90	120
Fatigue Resistance	Very Good	Moderate	Excellent
Processing Compatibility	Excellent	Good	Good
Cost Level	Medium	Low	High
Recyclability	Moderate	High	Moderate

6. Frequently Asked Questions (FAQ)

Q1: Can PVC foam core be used for vacuum infusion and RTM?
A: Yes, PVC foam is highly compatible with vacuum infusion, RTM, and hand lay-up processes, making it ideal for yachts, boats, and wind turbine blades.

Q2: What density should I choose for boat hulls?
A: For typical yacht decks and hulls, 80–120 kg/m³ is common. For lightweight superstructures, densities of 40–80 kg/m³ are often used.

Q3: How does PVC foam compare to PET foam in fatigue performance?
A: PVC foam generally has superior fatigue resistance and lower water absorption, making it better suited for marine and cyclic loading applications.

Q4: What is the minimum order quantity for PVC foam core from China?
A: Most Chinese manufacturers, including Jlon Composite, can supply small trial orders, but larger batches ensure stable quality and delivery efficiency.

Q5: Is PVC foam environmentally friendly?
A: PVC foam is recyclable and widely used, though PET foam has higher recycled content. The choice depends on your sustainability goals.

7. How to Choose the Right Foam Core

Choose PVC Foam Core if:

You need balanced mechanical performance

Your project involves marine or wind energy structures

You use vacuum infusion or RTM processes

Choose PET Foam Core if:

Cost sensitivity is critical

Sustainability is a key requirement

Your structure has relatively low dynamic loads

Choose SAN Foam Core if:

Your application demands high fatigue and temperature resistance

Performance outweighs cost considerations

Final Thoughts

There is no universal “best” foam core material. The right choice depends on structural requirements, processing methods, and budget.

For many composite manufacturers, PVC foam core remains the most versatile and widely used option, especially when sourced from experienced suppliers with stable quality control and export experience.