SAN Foam Core S (S-series)
Heat-treated state
also Core-Cell
Pick when maximum shear elongation and impact/slamming energy absorption are required (racing hulls, ice-class panels).
Values for the S condition
Other SAN Foam Core grades and fills
SAN Foam Core is listed in 8 conditions; see the grade overview at SAN Foam Core.
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 | — |
SThis page 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 | — | — |
What is SAN Foam Core S?
SAN Foam Core S is SAN Foam Core heat treated to S — pick when maximum shear elongation and impact/slamming energy absorption are required (racing hulls, ice-class panels). SAN Foam Core S has a tensile strength of 2 MPa (0.276 ksi), weaker than 92% of composite grades. The elastic modulus is 0.08 GPa (0.0109 Msi). SAN Foam Core S has a density of 0.09 g/cm³ (0.0033 lb/in³), lighter than 87% of composite grades. Its glass-transition temperature is 105°C (221 °F). M80 is the default condition FabDigit quotes; S is available on request or by drawing note.
Advantages
- Easy to machine — 92/100, better than 97% of composite grades
- Lightweight — 0.09 g/cm³ (0.0033 lb/in³), better than 87% 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 — 0.08 GPa (0.0109 Msi), worse than 93% of composite grades
- Poor heat conductor — 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 91% of composite grades
- Degrades in UV without stabilisers — 25/100, worse than 86% of composite grades
SAN Foam Core S properties
Typical room-temperature values for SAN Foam Core S; 13 are specific to this condition. Other listed values are SAN Foam Core reference data and may not represent this condition. Bars are the position among composite grades.
Physical3
SAN Foam Core S has a density of 0.09 g/cm³ (0.0033 lb/in³), lighter than 87% of composite grades. Its glass-transition temperature is 105°C (221 °F).
Mechanical7
SAN Foam Core S has a tensile strength of 2 MPa (0.276 ksi), weaker than 92% of composite grades. The elastic modulus is 0.08 GPa (0.0109 Msi).
Thermal8
SAN Foam Core S is rated for continuous service to 70°C (158 °F). It conducts heat at 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 91% 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 S 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's machinability is excellent (92/100, better than 97% of composite grades).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with SAN Foam Core S
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.
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.
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 |
SAN Foam Core S — frequently asked
What is SAN Foam Core S used for?
SAN Foam Core S 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 S?
SAN Foam Core S has a typical tensile strength of 2 MPa (0.276 ksi) — weaker than 92% of composite grades. Strength varies by condition: see the 8 listed tempers.
Is SAN Foam Core S 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 S 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 S?
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 S 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 S?
SAN Foam Core S 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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.