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SAERfoam®

SAERfoam® is an advanced lightweight structural core material developed by SAERTEX, combining ultralight foam cores with integrated 3D glass reinforcements to deliver enhanced mechanical performance, structural stability and process reliability.

Designed as an alternative to conventional core materials such as PVC, PET and balsa, SAERfoam® offers a highly engineered solution for lightweight sandwich structures across demanding composite applications.

The material combines low-density foam cores (PU, PE or PIR) with vertically integrated glass fibre bridges, creating a reinforced core structure with optimised stiffness, impactresistance and shear performance.

Key Benefits

  • Lightweight structural core solution

  • Excellent rigidity and stiffness-to-weight performance

  • Improved impact resistance and damage tolerance

  • Tailored mechanical properties to suit application requirements

  • Compatible with a wide range of resin systems

  • Easy to process across multiple manufacturing methods

  • Consistent and homogeneous material quality

  • Suitable for large-scale production environments

Product Range

Cristex supplies a range of SAERfoam® core materials suitable for RTM and resin infusion processes.

 

SAERfoam® 60 – RTM
Designed for resin transfer moulding applications, SAERfoam® 60 provides lightweight structural performance with excellent process compatibility.

 

SAERfoam® 80 – Resin Infusion
Developed for infusion applications, SAERfoam® 80 supports efficient resin distribution and laminate consistency in larger structural components.

 

SAERfoam®+
SAERfoam®+ is available in adaptable thicknesses ranging from approximately 8 mm to 30mm in 1 mm increments, allowing greater design flexibility for specialised applications.

 

Further information is available on request.

SAERTEX KITS 

SAERfoam® materials can also be supplied as part of SAERTEX KITS — ready-to-use, custom-cut solutions designed to improve manufacturing efficiency and reduce material waste.

Each kit is produced to customer specifications and supplied in the required lay-up sequence.

Benefits of SAERTEX KITS:

  • Reduced lay-up time

  • Lower material waste through nesting optimisation

  • Reduced labour costs

  • Precision CNC-cut parts for improved fit and consistency

  • Improved production efficiency and repeatability

Available Grades & Specifications

Below is a selection of our SAERfoam®. Additional specifications may be available on request.

Thickness (mm) Sheet Size (mm) Sheets per Box Datasheet
10 1200 × 1200 75
15 1200 × 1200 55
20 1200 × 1200 45
25 1200 × 1200 37
30 1200 × 1200 30
Thickness (mm) Sheet Size (mm) Sheets per Box Datasheet
10 1200 × 1200 75
15 1200 × 1200 55
20 1200 × 1200 45
25 1200 × 1200 37
30 1200 × 1200 30

Applications

SAERfoam® is widely used in lightweight sandwich structures where stiffness, weight reduction and structural consistency are critical, including:

  • Marine structures and hull construction

  • Wind energy components

  • Automotive and transport applications

  • Industrial composite panels

  • Aerospace and advanced lightweight structures

Its reinforced core architecture makes it particularly suitable for applications requiring improved structural efficiency and impact performance.

 

Looking for lightweight structural core solutions?

Speak to our team about SAERfoam® materials, processing support and custom kit options.

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