XPS density is typically 28–45 kg/m³, offering high compressive strength; PET foam ranges 80–250 kg/m³, providing high structural strength; PU foam is 30–60 kg/m³, best for insulation; PVC foam is 40–200 kg/m³, featuring good toughness. Selection principle: load-bearing structures require PET or high-density PVC; insulated walls need PU or XPS; impact-resistant panels use medium-density PVC. Low-density XPS suits floor insulation, while high-density PET can be used for wind turbine blades or vehicle body structures. Density directly affects flexural modulus and screw-holding capability, requiring comprehensive evaluation with face sheet thickness and bonding process.

