Epoxy Foam | Super Resin

Unique Capabilities of Our Epoxy Foam

Our proprietary epoxy foam is capable of forming ultra-thin and complex three-dimensional geometries that cannot be achieved with conventional foam cores without secondary machining. Its material properties can be tailored through customized resin formulations and it can be integrally molded with CFRP and other materials, expanding design possibilities across a wide range of applications.

Variable Thickness Molding

Variable Thickness Molding

Achieves continuous transitions between thick and ultra-thin sections without secondary machining. Complex geometries with localized thickness variations can be molded directly, enabling greater design flexibility while reducing manufacturing steps.

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Complex 3D Molding

Complex 3D Molding

Our proprietary foaming and molding process enables epoxy foam to conform to intricate three-dimensional geometries directly within the mold. This eliminates extensive post-machining, reduces manufacturing costs, and improves production efficiency.

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Ultra-Thin Molding

Ultra-Thin Molding

Supports molding from thicknesses of just several tens of micrometers, allowing for lightweight, high-precision components with exceptionally fine geometries.

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Thermal Formability

Thermal Formability

Unlike conventional thermoset foams, our epoxy foam can be thermally reshaped above its glass transition temperature (Tg). Once cooled, the material retains its new geometry, providing greater manufacturing flexibility without sacrificing structural performance.

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High Flexibility and Recovery

High Flexibility and Recovery

Although classified as a rigid epoxy foam, the material exhibits excellent flexibility and elastic recovery, allowing it to absorb deformation while maintaining its structural integrity.

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High Heat Resistance

High Heat Resistance

In addition to the 130°C grade, we also offer a grade of epoxy foam with higher heat resistance specifications of 180°C. Please contact us if you wish to use our epoxy foam in higher temperature environments.

Available in both standard 130°C Tg and high-temperature 180°C Tg grades to meet demanding thermal requirements across industrial, automotive, and aerospace applications.

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Precision Density Control

Precision Density Control

The expansion ratio can be precisely controlled to achieve the desired density, thickness, and mechanical performance.

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Custom Material Functionalization

Custom Material Functionalization

The desired filler can be added at the resin synthesis stage

Functional fillers and reinforcing additives can be incorporated during resin formulation to tailor mechanical, thermal, electrical, or other material properties for specific applications.

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Integrated Molding with CFRP and Other Materials

Integrated Molding with CFRP and Other Materials

Epoxy foam can be uniformly expanded and molded even within long, narrow structures.

The epoxy-based composition of the foam provides excellent compatibility with CFRP, enabling strong adhesion without requiring additional adhesives. It also bonds exceptionally well with metals such as aluminum, making it well suited for lightweight hybrid structures.

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Physical Properties of Proprietary Epoxy Foam (Tg = 130°C)

	Unit	240 kg/m³	120 kg/m³	60 kg/m³
Tensile Strength	MPa	3.5	2.1	0.6
Young’s Modulus	MPa	103.4	63.4	23.7
Elongation	%	7.4	7.7	5.0
Compressive Strength	MPa	3.3	1.2	0.4
Compressive Modulus	MPa	120.8	53.1	28.5

*The values shown are representative physical properties of epoxy foam with a glass transition temperature (Tg) of 130°C.

Available Thickness and Expansion Ratios

	Expansion Ratio: 5×	Expansion Ratio: 10×	Expansion Ratio: 20×
1 mm Thickness	✓	✓	Under Development
2 mm Thickness	✓	✓	✓

5× expansion: 240 kg/m³ (0.24 g/cm³)
10× expansion: 120 kg/m³ (0.12 g/cm³)
20× expansion: 60 kg/m³ (0.06 g/cm³)

Applications

Electronics

Housings for laptops, smartphones, and other portable electronic devices must be lightweight while providing sufficient impact resistance for everyday use. Our epoxy foam can be molded into curved, locally reinforced, and variable-thickness components measuring less than 1 mm thick. By integrating the foam core with CFRP in a single molded structure, we can produce electronic housings that are lighter and offer greater impact absorption than conventional designs.

Audio Equipment

Speaker diaphragms convert electrical signals into sound through vibration. High-performance diaphragms require materials that are lightweight, heat resistant, and have a high stiffness-to-weight ratio. By combining our ultra-thin epoxy foam with high-modulus materials, we develop lightweight diaphragm structures that meet these demanding requirements. We also offer a high-heat-resistant grade with a glass transition temperature (Tg) of 180°C.

Drones

Propeller guards protect drone propellers from contact with surrounding objects. However, because every gram affects flight time and battery performance, propeller guards must be as lightweight as possible. Our low-density epoxy foam can be molded into complex curved and three-dimensional shapes, enabling significant weight reduction in propeller guards and other structural components.

Sporting Goods

Sporting goods often require a combination of low weight, design flexibility, impact resistance, and energy absorption. Our epoxy foam can be engineered and molded to meet these requirements, making it suitable for advanced sports equipment designed to enhance both product performance and the user experience.

Automobiles

The automotive industry is increasingly replacing conventional metal components with CFRP and other lightweight materials to improve energy efficiency and vehicle performance. When used as a core material, our epoxy foam provides impact absorption while reducing overall component weight.

Industrial Machinery

Depending on the application, industrial equipment may require lightweight construction, impact absorption, heat resistance, thermal insulation, acoustic insulation, or a combination of these properties. We combine our epoxy foam with metals, CFRP, GFRP, and other materials to develop optimized hybrid structures for each application.

Other Applications

By adding new functionality to our epoxy foam and molding it together with other materials, it can be applied to a wide range of industries, including medical devices, optical equipment, aerospace, and many others.

Custom Epoxy Foam Development

We also provide custom epoxy foam development services to meet specific application requirements, including customized thickness, expansion ratio, and integrated molding with CFRP. Working closely with our customers, we develop optimized solutions tailored to each project’s technical and performance requirements. Please feel free to contact us to discuss your project.

Unique Capabilities of Our Epoxy Foam

Physical Properties of Proprietary Epoxy Foam (Tg = 130°C)

Available Thickness and Expansion Ratios

Applications

Custom Epoxy Foam Development

Epoxy Foam Inquiries