Phenolic Foam vs PVC Foam (Rigid, Structural Core)
Polymer · grade comparison
Phenolic Foam and PVC Foam (Rigid, Structural Core) are both polymer grades. PVC Foam (Rigid, Structural Core) is the stronger of the two: tensile strength 3 MPa (0.363 ksi) against 0.15 MPa (0.0218 ksi) for Phenolic Foam, about 17 times as much. PVC Foam (Rigid, Structural Core) is the more ductile: elongation 10% versus 2% for Phenolic Foam. Phenolic Foam is lighter (0.05 g/cm³ vs 0.08 g/cm³ for PVC Foam (Rigid, Structural Core)) and PVC Foam (Rigid, Structural Core) is stiffer (0.1 GPa vs 0.01 GPa). On the shop floor, PVC Foam (Rigid, Structural Core) welds better (poor vs not recommended) and Phenolic Foam sits in a lower cost tier (standard, $$) than PVC Foam (Rigid, Structural Core) (high, $$$$).
Phenolic FoamChoose it when weight is the constraint, or when the part sees heat.
PVC Foam (Rigid, Structural Core)Choose it when strength drives the design, or when the part is bent, formed or impact-loaded.
Phenolic Foam vs PVC Foam (Rigid, Structural Core): propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all polymer grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
How to read these bars
- One bar per material. A full bar is the highest value among all polymer grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
Phenolic FoamPVC Foam (Rigid, Structural Core)
Mechanical
Strength, stiffness, ductility and hardness at room temperature.
Elastic (Young's) Modulus
Poisson's Ratio
Tensile Strength (Ultimate)
Elongation at Break
Compressive Strength
Compressive Modulus
Flexural Strength
Flexural Modulus
Shear Strength
Shear Modulus
Yield Strength (0.2% offset)
Fracture Toughness (K_IC)
Physical
Density and transition temperatures.
Density
Water Absorption (24 h)
Water Absorption (Saturation)
Glass Transition (Tg)
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Thermal Expansion (CTE, 20–100 °C)
Max Service Temperature (continuous)
Min Service Temperature
Limiting Oxygen Index
Max Service Temperature (short-term)
Heat Deflection Temp. @ 0.45 MPa
Same in both: Specific Heat Capacity 1,400 J/kg·K0.33 BTU/lb·°F
Electrical
Conductivity and insulation.
Electrical Resistivity
Dielectric Constant (1 MHz)
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Corrosion Resistance
Same in both: UV / Weathering Resistance 30 / 100
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Weldability
Formability (cold)
Same in both: Machinability 90 / 100
Sustainability
Primary-production footprint per kilogram.
Same in both: Embodied Energy (primary production) 95 MJ/kg40,843 BTU/lb · Embodied Carbon (primary production) 4.5 kg CO₂/kg · Typical Recycled Content 0%
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Specific Stiffness (E / density)
Thermal Diffusivity
Same in both: Thermal Shock Resistance Index 0
Strength versus weight
Yield strength against density for every polymer grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | Phenolic Foam | PVC Foam (Rigid, Structural Core) |
|---|---|---|
| Default condition | — | — |
| Relative cost | $$ Standard | $$$$ High |
| Min. machined wall | — | — |
| Best machined surface | — | — |
Phenolic Foam vs PVC Foam (Rigid, Structural Core) — frequently asked
Is PVC Foam (Rigid, Structural Core) stronger than Phenolic Foam?
Yes. PVC Foam (Rigid, Structural Core) has a typical tensile strength of 3 MPa (0.363 ksi) against 0.15 MPa (0.0218 ksi) for Phenolic Foam — about 17 times as much.
Which is cheaper, Phenolic Foam or PVC Foam (Rigid, Structural Core)?
Phenolic Foam is the lower-cost material: it sits in the standard tier ($$) while PVC Foam (Rigid, Structural Core) is high ($$$$). Part price depends far more on geometry, tolerance and quantity than on raw stock — upload a CAD file for a live quote.
Which welds better, Phenolic Foam or PVC Foam (Rigid, Structural Core)?
PVC Foam (Rigid, Structural Core). Its weldability rates poor (15/100) against not recommended (1/100) for Phenolic Foam.
Ready to make it?
Upload a CAD file and FabDigit prices the part in Phenolic Foam and PVC Foam (Rigid, Structural Core) side by side — material, machining time, tolerance and finish in one quote. Certified material data ships with the order on request.
Typical handbook values for the conditions named above, normalised for comparison. Hardness on non-Brinell scales is converted approximately for charting only. Request certified data with your order for design-critical properties.