How does PET foam achieve “extremely low weight” and “high mechanical rigidity and stiffness” simultaneously?

This paradox is resolved through its closed-cell microstructure and the principles of sandwich theory. With densities typically ranging from 60 to 300 kg/m³, the PET core is a fraction of water’s weight. Despite this, it exhibits exceptional compressive and shear moduli. The key is the composite action: the low-density core resists shear forces and stabilizes the face sheets, while the thin, high-strength face sheets carry bending moments—functioning exactly like an I-beam. This configuration achieves a massive sectional moment of inertia with minimal mass, delivering an industry-leading specific strength and stiffness-to-weight ratio.


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