In-mold Foaming Cores for Net-Shape Production
Lightweight design is a key requirement for modern composite engineering. Rifeng E-Li is an innovative solution for fiber-reinforced sandwich structures with complex geometries that standard CNC machining cannot achieve.
By foaming directly in the mold, E-Li allows for total freedom of design, producing ready-to-use foam cores that perfectly match the mold cavity. This process significantly lowers the cost per part by reducing material waste, manual labor, and production cycle times.
In this specialized process, PMI pre-polymerization particles are crushed and pre-foamed to the desired density. These particles are then placed into a closed mold and heated, where they expand and deform to fill the entire cavity, resulting in a stable, high-precision shaped core upon cooling.
Processing and Production Stability
Rifeng E-Li is engineered for high-efficiency curing. It withstands temperatures up to 130 °C and pressures up to 3.5 MPa (depending upon density). Furthermore, it is perfectly suited for aerospace curing conditions requiring high compressive creep resistance at 180 °C and 0.7 MPa. It is the premier choice for RTM, wet pressing, and high-pressure RTM (Compression-RTM) processes.
Density Tailored to Your Specifications
To meet specific mechanical requirements, the core density can be precisely adjusted during the foaming process. We offer a tailored density range between 75 kg/m³ and 150 kg/m³, with higher density options up to 300 kg/m³ available upon request.
High Volume Production At Lower Unit Costs
• Freedom of design for complex, non-machinable geometries.
• Function integration: inserts, custom surface finishes, and resin flow channels.
• High compression strength and temperature resistance at low densities.
• Full compatibility with fast-curing industrial processes.
• Completely free of hazardous ingredients.
Mechanical Properties (Typical Values)
|
Property |
Test Method |
Unit |
Rifeng 75 E-Li |
Rifeng 110 E-Li |
Rifeng 150 E-Li |
Rifeng 200 E-Li |
Rifeng 300 E-Li |
| Density | ISO 845 | Kg/m³ | 75 | 110 | 150 | 200 | 300 |
| Compressive Strength | ISO 844 | MPa | 1.0 | 1.8 | 3.0 | 3.9 | 5.9 |
| Tensile Strength | ASTM D638 | MPa | 0.9 | 1.6 | 2.1 | 2.8 | 3.9 |
| Elastic Modulus | ASTM D638 | MPa | 80 | 140 | 210 | 270 | 416 |
| Elongation at Break | ASTM D638 | % | 1.9 | 1.8 | 1.7 | 1.6 | 1.4 |
| Flexural Strength | ASTM D790 | MPa | 1.0 | 2.3 | 3.0 | 4.0 | 5.0 |
| Shear Strength | ASTM C273 | MPa | 0.6 | 1.2 | 1.7 | 2.4 | 3.6 |
| Shear Modulus | ASTM C273 | MPa | 35 | 45 | 65 | 90 | 124 |
| Compressive Creep | GB/T15048 | % | ≤2.0 | ≤2.0 | ≤2.0 | ≤2.0 | ≤2.0 |
| Glass transition Temp (Tg) | DIN 53424 | ℃ | 210 | 205 | 196 | 190 | 170 |
Product Advantages
