ROHACELL-71-WF (2500MM X 1250MM X 50.8MM SHEET)

ROHACELL® WF / WF-HT PMI Structural Foam Core

Overview

ROHACELL® WF and WF-HT are polymethacrylimide (PMI) structural foam core materials specifically engineered for demanding aerospace sandwich composite applications. Designed for use in autoclave, vacuum infusion, RTM, and VARTM manufacturing processes, these lightweight closed-cell foam cores provide excellent mechanical performance, dimensional stability, and weight savings while supporting co-curing production methods. The material has been used in aerospace programs for more than 30 years and complies with numerous aerospace specifications including MIL-PRF-46194A.

Key Technical Characteristics

• Base Material: Polymethacrylimide (PMI) structural foam
• Product Grades: 51 WF, 71 WF, 110 WF, 200 WF, 300 WF*
• Density Range: 52-300 kg/m� (3.25-18.7 lb/ft�)
• Closed-Cell Foam Structure
• Processing Temperature:
  • WF: Up to 130°C (266°F)
  • WF-HT: Up to 180°C (356°F) after heat treatment
• Maximum Processing Pressure: 0.7 MPa (102 psi)
• Manufacturing Compatibility:
  • Autoclave processing
  • Vacuum infusion
  • RTM (Resin Transfer Molding)
  • VARTM (Vacuum Assisted Resin Transfer Molding)
• Aerospace Specifications: MIL-PRF-46194A, WL 5.1460, WL 5.1461 and others

Core Performance Benefits

• Supports single-step co-curing manufacturing processes
• Reduces composite production costs by up to 25%
• Provides weight reductions of up to 20% versus alternative sandwich core solutions
• Closed-cell structure minimizes unwanted resin absorption
• Excellent thermal and mechanical properties in all three dimensions
• Near-isotropic performance characteristics
• Eliminates the need for local potting or reinforcement in many edge and load-introduction areas
• High dimensional stability under elevated temperature processing conditions

Typical Applications

• Aircraft structural sandwich panels
• Primary and secondary aerospace composite structures
• Autoclave-cured composite assemblies
• RTM and VARTM aerospace components
• Interior and exterior aircraft composite parts
• High-performance lightweight structural panels
• Complex aerospace sandwich constructions requiring high stiffness-to-weight ratios

Material Engineering & Design Features

ROHACELL® WF/WF-HT utilizes PMI foam technology engineered specifically for aerospace manufacturing environments. The closed-cell structure prevents excessive resin uptake during composite processing, ensuring resin remains concentrated at the core-to-skin interface where it contributes most effectively to structural performance.

The material offers a broad range of densities to optimize weight and mechanical performance requirements:

• 51 WF: Ultra-lightweight core for maximum weight reduction
• 71 WF: Lightweight structural core with enhanced strength
• 110 WF: Balanced mechanical and weight performance
• 200 WF: High-strength structural applications
• 300 WF: Maximum strength and stiffness applications*

Typical mechanical performance ranges include:

• Compressive Strength: 0.6-17.8 MPa
• Tensile Strength: 1.6-12.0 MPa
• Shear Strength: 0.8-8.3 MPa
• Elastic Modulus: 75-580 MPa
• Shear Modulus: 20-360 MPa

Installation & Handling

• Suitable for co-curing composite manufacturing processes
• Can be thermoformed into complex geometries
• Readily CNC machined for precision core fabrication
• Compatible with autoclave and infusion processing technologies
• Available as pre-shaped, ready-to-install foam core components through specialized shaping services
• WF-HT grades require heat treatment prior to high-temperature processing applications

Environmental & Compliance Notes

• Designed for aerospace-certified manufacturing environments
• Complies with multiple aerospace material specifications
• Closed-cell construction minimizes resin waste during manufacturing
• Technical values represent typical properties for nominal density grades
• *300 WF grade availability is limited to the Americas region

Key Advantages for Aerospace Use

• Industry-proven PMI aerospace foam technology with over 30 years of service history
• Enables lighter sandwich composite structures without sacrificing strength
• Supports high-temperature aerospace composite curing cycles
• Reduces manufacturing costs through co-curing capabilities
• Excellent compatibility with advanced composite manufacturing methods
• Outstanding machinability and thermoformability for complex designs
• Reduces resin consumption and unnecessary structural weight
• Provides highly efficient stiffness-to-weight performance for aerospace structures