SAN Foam Core
also Core-Cell
SAN Foam Core is a closed-cell styrene-acrylonitrile thermoplastic foam (Core-Cell type) offered in M60 to M200 density grades plus A, S, T and CC series.
Reference datasheet — SAN Foam Core is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the M80 condition
SAN Foam Core grades and fills
SAN Foam Core is supplied in 8 conditions, soft to hard. M80 is the default FabDigit quotes; the values on this page are for it.
Compare all 8 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
60 kg/m³ marine SAN foam | Lightest structural grade for lightly loaded decks, interior panels and weight-critical racing structures. | 1 | |||
M80Default 80 kg/m³ marine SAN foam | The default hull and deck core density: best balance of shear toughness, weight and resin uptake for infusion. | 2 | |||
Solution annealed | Legacy/general-purpose Corecell A-Foam family for production boats and panels where cost matters more than peak toughness. | 2 | 8 | ||
S-series | Pick when maximum shear elongation and impact/slamming energy absorption are required (racing hulls, ice-class panels). | 2 | 8 | ||
100 kg/m³ marine SAN foam | Higher-density core for slamming areas, bottom panels and locally loaded zones. | 2 | |||
T-series | Use for composite tooling and any laminate that must be post-cured well above standard marine-core limits. | 2 | 5 | ||
130 kg/m³ marine SAN foam | For highly loaded bottom panels, bulkhead intersections and transition zones near hard points. | 3 | |||
200 kg/m³ high-density SAN foam | Insert-grade density for hard points, engine beds, fastener bosses and heavily compressed zones. | 4 |
Supply forms, finishes and certifications
Ways SAN Foam Core is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
CC | Contour-cut / grid-scored & perforated sheet | Surface finish |
What is SAN Foam Core?
SAN Foam Core is a closed-cell styrene-acrylonitrile thermoplastic foam (Core-Cell type) offered in M60 to M200 density grades plus A, S, T and CC series. The default 0.084 g/cm³ grade gives 1.7 MPa tensile strength, 0.066 GPa modulus and 0.036 W/m·K conductivity, and it is chosen over cross-linked PVC foam for higher shear elongation and impact tolerance, supplied as flat sheet, grid-scored drapable sheet and blocks. Maximum service temperature is 70 °C, which rules out autoclave cure; the foam is also not UV stable, so PMI foam is the high-temperature alternative. SAN Foam Core has a density of 0.08 g/cm³ (0.003 lb/in³), lighter than 89% of composite grades. Its glass-transition temperature is 105°C (221 °F). SAN Foam Core has a tensile strength of 2 MPa (0.247 ksi), weaker than 94% of composite grades. The elastic modulus is 0.07 GPa (0.0096 Msi).
What is SAN Foam Core used for?
- boat hulls
- wind blades
- impact-critical marine panels
Advantages
- Easy to machine — 92/100, better than 97% of composite grades
- Lightweight — 0.08 g/cm³ (0.003 lb/in³), better than 89% of composite grades
- Low embodied carbon — 4.5 kg CO₂/kg, better than 79% of composite grades
Limitations
- Limited service temperature — 70°C (158 °F), worse than 98% of composite grades
- Low stiffness — 0.07 GPa (0.0096 Msi), worse than 94% of composite grades
- Poor heat conductor — 0.04 W/m·K (0.0208 BTU/hr·ft·°F), worse than 92% of composite grades
- Degrades in UV without stabilisers — 25/100, worse than 86% of composite grades
SAN Foam Core properties
Typical room-temperature values for SAN Foam Core-M80; bars are the position among composite grades.
Physical3
SAN Foam Core has a density of 0.08 g/cm³ (0.003 lb/in³), lighter than 89% of composite grades. Its glass-transition temperature is 105°C (221 °F).
Mechanical7
SAN Foam Core has a tensile strength of 2 MPa (0.247 ksi), weaker than 94% of composite grades. The elastic modulus is 0.07 GPa (0.0096 Msi).
Thermal8
SAN Foam Core is rated for continuous service to 70°C (158 °F). It conducts heat at 0.04 W/m·K (0.0208 BTU/hr·ft·°F), worse than 92% of composite grades. Thermal expansion is 60 µm/m·K (33.3 µin/in·°F).
Electrical2
Chemical & Environmental2
UV resistance is poor.
Sustainability3
Producing a kilogram of SAN Foam Core takes about 105 MJ of energy and emits 4.5 kg of CO₂ — less than 63% of composite grades. Typical recycled content is 0%.
Manufacturability1
SAN Foam Core's machinability is excellent (92/100, better than 97% of composite grades).
Common Calculations4
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the composite family
Yield strength against density for every composite grade FabDigit runs. SAN Foam Core is highlighted; hover a dot for its name, or open the interactive family chart.
Working with SAN Foam Core
Is SAN Foam Core easy to machine?
Cuts easily with band saw, hot knife or CNC router at high feed; use dust extraction and avoid melting by keeping tools sharp and speeds moderate.
Can SAN Foam Core be welded?
Not weldable in the metallic sense; panels are butt-joined with epoxy/polyester bonding paste or thermally fused splices supplied by the producer.
Can SAN Foam Core be formed, bent or molded?
Thermoformable/drapable when warmed to roughly 90–110 °C; for cold drape over compound curvature use grid-scored or double-cut sheet with vacuum bagging.
SAN Foam Core chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| styreneSAN copolymer backbone | 68 – 78 | 73 |
| acrylonitrileraises toughness, solvent and styrene resistance | 22 – 32 | 27 |
| blowing agent / additives residuecell gas, nucleants, stabilizers | 0 – 2 | 1 |
What surface finishes work on SAN Foam Core?
Sand faces lightly to remove skin and dust, prime pinholes with thickened resin, then laminate or infuse skins; the raw foam must never be left UV-exposed.
Equivalent designations
Standards and trade names that resolve to SAN Foam Core in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- Trade names
- Core-Cell
How much does SAN Foam Core cost?
SAN Foam Core is a high-cost composite ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
SAN Foam Core — frequently asked
What is SAN Foam Core used for?
SAN Foam Core is typically used for boat hulls, wind blades and impact-critical marine panels. In short: toughest thermoplastic marine core; better impact than PVC foam; compatible with styrene resins.
What is the tensile strength of SAN Foam Core?
SAN Foam Core has a typical tensile strength of 2 MPa (0.247 ksi) — weaker than 94% of composite grades. Strength varies by condition: see the 8 listed tempers.
Is SAN Foam Core easy to machine?
Yes — machinability is rated excellent (92/100, better than 97% of composite grades). Cuts easily with band saw, hot knife or CNC router at high feed; use dust extraction and avoid melting by keeping tools sharp and speeds moderate.
Can SAN Foam Core be welded?
Not weldable in the metallic sense; panels are butt-joined with epoxy/polyester bonding paste or thermally fused splices supplied by the producer.
What surface finishes work on SAN Foam Core?
Sand faces lightly to remove skin and dust, prime pinholes with thickened resin, then laminate or infuse skins; the raw foam must never be left UV-exposed.
Can SAN Foam Core be formed, bent or molded?
Thermoformable/drapable when warmed to roughly 90–110 °C; for cold drape over compound curvature use grid-scored or double-cut sheet with vacuum bagging.
What is the maximum service temperature of SAN Foam Core?
SAN Foam Core is rated for continuous use to about 70°C (158 °F), and briefly to 90°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
How much does SAN Foam Core cost?
SAN Foam Core is a high-cost composite ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- Corecell M-Foam structural core datasheet — Gurit (2023)
- Core-Cell SAN foam core technical data — ATL Composites / Gurit (2022)
- ASTM C273 Shear Properties of Sandwich Core Materials — ASTM (2020)
- ASTM D1621 Compressive Properties of Rigid Cellular Plastics — ASTM (2016)
- ASTM D1623 Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics — ASTM (2017)
- ASM Handbook Vol. 21: Composites — Sandwich Core Materials — ASM International (2001)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.