PC-Foam
PC-Foam is polycarbonate expanded chemically (CBA) or physically (nitrogen/MuCell) for structural foam molding, with low-density, glass-filled, V-0, UV and foam-sheet conditions on file.
Reference datasheet — PC-Foam 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 SF-CBA condition
PC-Foam grades and fills
PC-Foam is supplied in 5 conditions, soft to hard. SF-CBA is the default FabDigit quotes; the values on this page are for it.
Compare all 5 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
Low-density structural foam, 25–40 % weight reduction | Maximum weight and resin saving for very thick, lightly loaded panels and cores; accept the large drop in strength and impact. | 30 | 6 | ||
Flame-retardant foamed PC, UL 94 V-0 | Required for electrical enclosures, IT/telecom housings and rail interiors where a V-0 rating at the actual wall thickness must be certified. | 40 | 42 | 12 | 62 HRM |
SF-CBADefault Chemical-blown structural foam, 10–20 % weight reduction | Standard low-pressure structural foam molding with a CBA masterbatch — pick for thick-wall covers, enclosures and pallets where sink-mark-free rigidity matters more than surface finish. | 43 | 45 | 18 | 62 HRM |
MuCell / microcellular | Choose when tight dimensional control, thin walls and near-solid surface quality are needed alongside modest weight and cycle-time savings. | 53 | 55 | 25 | 68 HRM |
20 % glass-fiber reinforced structural foam | Use when a foamed part still needs high stiffness, low creep and low CTE — e.g. load-bearing housings and machine bases. | 70 | 2.5 |
Supply forms, finishes and certifications
Ways PC-Foam is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
FOAM-SHEET | Extruded PC foam sheet / board | Supply form |
UV | UV-stabilized / weatherable foamed PC | Grade option |
What is PC-Foam?
PC-Foam is polycarbonate expanded chemically (CBA) or physically (nitrogen/MuCell) for structural foam molding, with low-density, glass-filled, V-0, UV and foam-sheet conditions on file. It cuts weight and resin use in large, thick-wall parts while keeping bending rigidity through a dense skin over a cellular core; typical values are about 1 g/cm³ density, 45 MPa tensile strength, 18 % elongation and 115 °C maximum service temperature. Walls must run 4–10 mm, joint strength drops to roughly 40–60 % of solid PC, and as-molded swirl means most parts are painted; solid or mineral-filled PC is the choice where surface finish is critical. PC-Foam has a density of 1 g/cm³ (0.0361 lb/in³), lighter than 73% of polymer grades. Its glass-transition temperature is 147°C (297 °F). PC-Foam has a yield strength of 43 MPa (6.24 ksi) and a tensile strength of 45 MPa (6.53 ksi) — weaker than 61% of polymer grades. Elongation at break is 18% and the elastic modulus is 1.8 GPa (0.261 Msi).
What is PC-Foam used for?
- large enclosures
- furniture components
- equipment panels
- weight-reduced structural parts
Limitations
- Hard to polish — 20/100, worse than 95% of polymer grades
- Poor heat conductor — 0.16 W/m·K (0.0924 BTU/hr·ft·°F), worse than 78% of polymer grades
PC-Foam properties
Typical room-temperature values for PC-Foam-SF-CBA; bars are the position among polymer grades.
Physical4
PC-Foam has a density of 1 g/cm³ (0.0361 lb/in³), lighter than 73% of polymer grades. Its glass-transition temperature is 147°C (297 °F).
Mechanical16
PC-Foam has a yield strength of 43 MPa (6.24 ksi) and a tensile strength of 45 MPa (6.53 ksi) — weaker than 61% of polymer grades. Elongation at break is 18% and the elastic modulus is 1.8 GPa (0.261 Msi).
Thermal11
PC-Foam is rated for continuous service to 115°C (239 °F). It conducts heat at 0.16 W/m·K (0.0924 BTU/hr·ft·°F), worse than 78% of polymer grades. Thermal expansion is 68 µm/m·K (37.8 µin/in·°F).
Electrical7
PC-Foam is an electrical insulator with a dielectric strength of 18 kV/mm (457.2 V/mil) and a resistivity of 1×10¹⁴ Ω·m.
Chemical & Environmental3
Corrosion resistance is very good (82/100), better than 56% of polymer grades. UV resistance is fair.
Sustainability4
Producing a kilogram of PC-Foam takes about 105 MJ of energy and emits 6 kg of CO₂ — more than 54% of polymer grades. Typical recycled content is 10%.
Manufacturability8
PC-Foam's machinability is good (62/100, better than 60% of polymer grades); weldability fair (50/100); formability poor (30/100).
Common Calculations5
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 polymer family
Yield strength against density for every polymer grade FabDigit runs. PC-Foam is highlighted; hover a dot for its name, or open the interactive family chart.
Working with PC-Foam
Is PC-Foam easy to machine?
Cuts easily with sharp single-flute or O-flute tools and high rake; use light climb passes and avoid heat build-up, and expect exposed open cells at cut edges that must be sealed or edge-banded.
Can PC-Foam be welded?
Hot-plate, ultrasonic (near-field, low amplitude) and vibration welding all work only through the dense skin — joint strength is roughly 40–60 % of solid PC; solvent bonding with methylene-chloride blends or 2K PUR/epoxy adhesives is more reliable.
Can PC-Foam be formed, bent or molded?
Low-pressure structural foam or gas-counterpressure molding on a nitrogen or CBA-equipped machine; dry resin ≤0.02 % moisture (120 °C, 4 h), melt 265–305 °C, mold 55–95 °C, wall 4–10 mm, fast fill with short shot plus 10–20 % expansion.
PC-Foam 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 |
|---|---|---|
| chemical blowing agent masterbatchendothermic sodium bicarbonate/citric acid or exothermic azodicarbonamide type; replaced by N₂/CO₂ gas in physical (MuCell) foaming | 0.3 – 3 | 1 |
| nucleating agent / talccell-size control | 0 – 1 | 0.3 |
| heat and hydrolysis stabilizer (phosphit | 0.05 – 0.5 | 0.2 |
| glass fiberonly in reinforced foam variants (GF10–GF30) | 0 – 30 | 0 |
| flame retardant (sulfonate salt / phosphFR V-0 variants only | 0 – 12 | 0 |
| bisphenol-A polycarbonatemelt-polycondensation or interfacial BPA-PC resin, typically 8–20 g/10 min MFR foam grade | ≥ 96 (balance) |
What surface finishes work on PC-Foam?
As-molded swirl and silver streaks are normal: standard route is sand/fill, adhesion-promoter primer, then 2K PU or waterborne topcoat; gas-counterpressure or in-mold film gives a paintable class-B surface, and PC foam accepts vacuum metallizing only after sealing.
How much does PC-Foam cost?
PC-Foam is a standard-cost polymer ($$), cheaper than about 71% 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.
PC-Foam — frequently asked
What is PC-Foam used for?
PC-Foam is typically used for large enclosures, furniture components, equipment panels and weight-reduced structural parts. In short: lightest structural PC; thick-wall low-pressure molding; rigid weight-saving enclosure resin.
What is the yield strength of PC-Foam?
PC-Foam has a typical yield strength of 43 MPa (6.24 ksi) and a tensile strength of 45 MPa (6.53 ksi) — weaker than 61% of polymer grades. Strength varies by condition: see the 5 listed tempers.
Is PC-Foam easy to machine?
Reasonably — machinability is rated good (62/100, better than 60% of polymer grades). Cuts easily with sharp single-flute or O-flute tools and high rake; use light climb passes and avoid heat build-up, and expect exposed open cells at cut edges that must be sealed or edge-banded.
Can PC-Foam be welded?
With care — weldability is rated fair (50/100). Hot-plate, ultrasonic (near-field, low amplitude) and vibration welding all work only through the dense skin — joint strength is roughly 40–60 % of solid PC; solvent bonding with methylene-chloride blends or 2K PUR/epoxy adhesives is more reliable.
What surface finishes work on PC-Foam?
As-molded swirl and silver streaks are normal: standard route is sand/fill, adhesion-promoter primer, then 2K PU or waterborne topcoat; gas-counterpressure or in-mold film gives a paintable class-B surface, and PC foam accepts vacuum metallizing only after sealing.
Can PC-Foam be formed, bent or molded?
Low-pressure structural foam or gas-counterpressure molding on a nitrogen or CBA-equipped machine; dry resin ≤0.02 % moisture (120 °C, 4 h), melt 265–305 °C, mold 55–95 °C, wall 4–10 mm, fast fill with short shot plus 10–20 % expansion.
What is the maximum service temperature of PC-Foam?
PC-Foam is rated for continuous use to about 115°C (239 °F), and briefly to 135°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between PC-Foam SF-CBA and PC-Foam MUCELL?
SF-CBA is the default condition — standard low-pressure structural foam molding with a CBA masterbatch — pick for thick-wall covers, enclosures and pallets where sink-mark-free rigidity matters more than surface finish. MUCELL: choose when tight dimensional control, thin walls and near-solid surface quality are needed alongside modest weight and cycle-time savings. Yield strength is 43 MPa in SF-CBA versus 53 MPa in MUCELL.
How much does PC-Foam cost?
PC-Foam is a standard-cost polymer ($$), cheaper than about 71% 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
- Engineered Materials Handbook Vol. 2: Engineering Plastics — ASM International (1988)
- Handbook of Polymeric Foams and Foam Technology — Hanser (2004)
- ISO 7391 Plastics — Polycarbonate (PC) moulding and extrusion materials — ISO (2006)
- ASTM D3935 Standard Classification System for Polycarbonate Molding and Extrusion Materials — ASTM (2017)
- CAMPUS plastics database — polycarbonate injection grades — CWFG / CAMPUS consortium (2024)
- Structural foam and microcellular (MuCell) processing guides for polycarbonate — Covestro / SABIC / Trexel (2023)
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.