Processing & Services

ROHACELL® has a closed-cell structure in which only the cut cells at the surface are filled with resin. This saves unnecessary weight caused by permeating resin and also ensures adequate bonding to the facings. ROHACELL® is available in various grades such as WF, RIST-HT, and RIMA, which differ mainly in cell size and therefore in resin uptake. The use of ROHACELL® allows a co-curing process in which the facings are cured and bonded to the core material in a single work step. Unlike with other core materials ROHACELL® does not depend on stabilizing agents, potting materials or additional stabilization cure cycles to provide lateral strength as this is already an inherent property of the foam. ROHACELL®’s homogenous cell structure provides zero print through to the composite face sheets leaving a class A surface finish every time. All this reduces work steps, cycle times and processing costs.

Our technical team supports your product development with a wide range of material data and application experience for special processes and top-notch composites applications. For special requirements we are open to run material qualification programs with our qualified test laboratories. We can support your prototype fabrication and small production runs, plus we can conduct sandwich structure testing and experiments. With experience in forming technologies, liquid composite molding, autoclaving and other processes, our experts can demonstrate the use of performance foams with traditional and non-traditional techniques. Customer product training is also available.

Our team is equipped to produce net-shaped foam cores with high precision, to any geometry you require. This can be done either by CNC machining or thermoforming. Our Shape Departments are equipped with multiple 5-axis large format CNC machines and multi-spindle CNC machines. Evonik’s in-house experts can advise on economical options for bonding, thermoforming and CNC machining of shapes for your applications. Advice on pre-process management is also available, including moisture management, drying, heat treatment and FOD control. Plus, we can set up your logistics plan to make sure you receive your shapes “just-in-time” and “ready-to-use” with an optimized packaging concept designed just for you.
If you are interested in thermoforming your parts, we can support you with conventional thermoforming with high temperature tooling, thermoforming with low temperature tooling or thermoshaping with compression.