An FRP Foam Core Sandwich Panel is a high-performance composite material consisting of three layers: two strong, durable Fiber Reinforced Polymer (FRP) skins bonded to a lightweight, insulating foam core (typically XPS, Polyurethane/PUR, or Polyisocyanurate/PIR). This structure creates an extremely high strength-to-weight ratio, similar to an I-beam.
It is primarily manufactured via two processes:
- Continuous Lamination: A automated, high-volume process where the FRP layers (resin-saturated glass fiber mats) are applied to the moving foam core, pressed between belts, and cured in an oven. This produces consistent, long panels ideal for walls and roofs.
- Vacuum Bag Molding (Intermittent): Used for custom, complex, or thicker panels. The layers are assembled in a mold, covered with a vacuum bag, and the air is extracted. Atmospheric pressure compresses the layers while the resin cures, ensuring excellent bond quality and low void content.
