ROHACELL®
Making the world lighter
High-performance foam cores for sandwich structures
Lightweight composite
sandwich constructions
with ROHACELL®
Evonik, the creative industrial group from Germany, is one of
the world leaders in specialty chemicals. Its activities focus on
the key megatrends health and nutrition, resource efficiency
and globalization. Evonik is active in over 100 countries around
the world.
With ROHACELL® structural foam lightweight sandwich
structures can be realized resulting in super-light structures that
display high shear and pressure resistance, even at elevated
temperatures.
Light and strong
The principle of increasing stiffness of a composite
structure by means of sandwich construction is well
established. ROHACELL®, PMI-based structural
foam has been used in fiber reinforced composite
technology for more than 40 years. And it is by no
coincidence that ROHACELL® is still a leader in the
area of high performance lightweight sandwich
construction today. ROHACELL®’s success is attributed
to the following:
• Excellent mechanical properties over a wide
temperature and density range.
• High temperature resistance up to 220 °C (428 °F)
• Excellent compressive creep behavior up to 180 °C
(356 °F) and 1.0 MPa (145 psi)
• Excellent dynamic strength and fatigue behavior
• Cell size options for process method optimization
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The optimum product to realize your success
ROHACELL® grades
ROHACELL® IG/IG-F
sporting goods, medical, automobile applications
ROHACELL® SL
sporting goods, automobile applications
ROHACELL® HERO
highest elongation, minimized resin absorption
ROHACELL® A
aircraft applications, curing up to 125 °C and 0.35 MPa
ROHACELL® WF*
aircraft applications, curing up to 180 °C and 0.7 MPa
ROHACELL® RIST*
designed for Resin Infusion, STructural application
ROHACELL® RIMA*
designed for Resin Infusion, Minimized Resin Absorption
ROHACELL® XT*
eXTended temperature, curing up to 190 °C and 0.7 MPa
ROHACELL® HP*
highest creep resistance, e.g, 32 kg/m³, 180 °C and vacuum
ROHACELL® S
good fire behavior, railcars, ship, smaller aircraft
ROHACELL® EC
absorbs electromagnetic waves at radar frequencies
ROHACELL® HF
antennas, radomes, medical
ROHACELL® WIND-F
wind turbine blades
Used mainly
in aircraft
* HT grade available
Added Value
with ROHACELL®
Aerospace applications
•Stable, uniform and reliable
during fabrication
•Reduced fabrication time
•Co-curing, no core
stabilization required
•High specific strength
•Outstanding creep
compression resistance
Antennas and radomes
•Dielectric properties close to air
•High specific properties while
maintaining transparency
•Tightest dimensional tolerances
for optimum antenna performance
Automotive industry
•Efficient thermoshaping process
•Short cycle times by RTM or
with thermoplastic layers
•Effective light weight design
•Reduction of fuel consumption
and CO2 emission
•Extended range and thermal
insulation for EV’s
Medical technology
•No inclusion due to homoge neous structure
•Stable and reliable process
•Lightweight and handy
imaging beds
•High quality X-ray/CT image
with minimal patient radiation
exposure due to low Al-equivalent
Railcars
•Low energy consumption and
high accelerations due to
lightweight structure
•Good FST properties (no smoke,
no toxic gasses)
•Extended passenger space
Sports and leisure
•Lightweight design resulting in
top performance and endurance
•High specific mechanical properties
•Design freedom
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We support you.
We support your use of
ROHACELL® in all composite
manufacturing processes.
Low viscosity resin
RTM
closed mold
For the best possible support of our
customers, the ROHACELL® solution center
offers you a variety of options to incorporate
ROHACELL® efficiently in your design work.
LRI
single side mold
We support you
in developing
automation concepts
with ROHACELL®.
Sandwich Technology Center
We can support your prototype fabrication, small production
runs, and can conduct sandwich structure testing and
experiments, e.g., thermoforming, liquid composite molding
and autoclaving etc.. We are able to demonstrate the use of
ROHACELL® using traditional and non-traditional
techniques. In addition, we offer samples and customer
product training.
Take advantage of our knowhow:
We can help you with
• Reducing cycle time in production
• Selection of right shaping method
(thermoforming and/or CNC machining)
• Stable and reliable curing process
• Cost saving concepts
• Shorter development cycles
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Mid and high viscosity resin
Prepreg
RFI single side mold
Feeding system skins
and ROHACELL®
Cutting
Press-Mold
closed mold
Heating
Vacuum
thermoforming
Cooling
Trimming
and cutting
Handling
by robotics
Removing
Increase your efficiency
Utilize the advantages of ROHACELL®
for your lightweight constructions and
optimize your processes.
Stay cool
The benchmark is 180 °C (356 °F) and
1.0 MPa (145 psi). ROHACELL® can
reduce the curing process to a single step.
With its high thermal stability and creep
compression strength the structural foam
sets new standards in processing.
Reduce your lay-up efforts
Shortened lay-up time helps achieve cost
savings of up to 50 % in comparison to
the honeycomb structure.
Design without limits
Design and produce composite components with the greatest of ease. With
ROHACELL® you can optimize integral
construction.
Whether by thermoforming or high-speed
CNC machining, ROHACELL® eliminates
geometric challenges by combining creativity and mechanical effectiveness.
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ROHACELL® SHAPES
Department
The ROHACELL® SHAPES department produces high precision shaped
foam cores to any geometry you may
require.
This can be done by CNC machining
and/or thermoforming.
Our competences
in Shapes
Engineering service
• ITAR certified facility at ROHACELL®
production site in Mobile, AL, USA only
• Ftp site data transfer
• CAD data transfer to CNC data 2D/3D
• Generating CNC data
• Prototype and serial production
Pre-process management
• Moisture/environmental management
•Drying
• Heat treatment
Thermoforming
• Cold/hot forming
• Thermoforming tool concept
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CNC machining
• 4 axis/5 axis
Quality management
• First Article Inspection (FAI) reporting
• Certificate of conformity for each delivery
• Digital measurement with “FARO” arm
• Process control documentation
• Reproducible quality
Logistics
• Just in time delivery
• Ready to use and clearly labeled shapes
• Optimized packaging concept
Your benefits
• Focus on your core business
• No bound capital, no scrap parts
• Reduce your finished part cost up to 30 %
• Decrease lead time by not using a CNC
machining third-party
ROHACELL® contacts
all over the world
Germany
Global office
phone +49 6151 18 1005
[email protected]
Italy
Alessio Redolfi
phone +33 02 99070549
[email protected]
Belgium, Netherlands
Ron van Hoorn
phone +31 6 129 42 791
[email protected]
United Kingdom
Hameem Yasin
phone +44 789 0536 447
[email protected]
France, Spain
Laurent Miotto
phone +33 607244716
[email protected]
Israel
Aviad Aronson
phone +972 52 5702089
[email protected]
USA/Canada (Eastern),
South America
Reid Averill
phone +1 901 651 7675
[email protected]
USA/Canada (Western),
Mexico
Blake Juhl
phone +1 801 495 9403
[email protected]
Brazil
Fabio Tufano
phone +55 11 3146 9815
[email protected]
China
Jacky Yang
phone +86 21 6119 1373
[email protected]
Japan
Teiji Ito
phone +81 80 2090 2773
[email protected]
India
Vikas Rane
phone +91 22 6723 8810
[email protected]
South Korea
David Baek
phone +82 10 9052 0180
[email protected]
You can find further
contact persons at
www.rohacell.com > contact.
Darmstadt
Mobile
Shanghai
Highest quality standard
We have an integrated management system in place to
meet global customer requirements and ensure that the
highest quality standards are maintained.
Our system is ISO 9001: 2008, ISO 14001: 2004,
BS OHASAS 1800:2007 and EN 9100: 2009-certified
and is regularly optimized.
Our US location can produce ITAR related projects.
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This information and all technical and
other advice are based on Evonik’s
present knowledge and experience. However, Evonik assumes no liability for
such information or advice, including
the extent to which such information or
advice may relate to third party intellectual property rights. Evonik reserves the
right to make any changes to information or advice at any time, without prior
or subsequent notice. Evonik disclaims
all representations and warranties,
whether express or implied, and shall
have no liability for, merchantability of
the product or its fitness for a particular
purpose (even if Evonik is aware of
such purpose), or otherwise. EVONIK
SHALL NOT BE RESPONSIBLE FOR
CONSEQUENTIAL, INDIRECT OR
INCIDENTAL DAMAGES (INCLUDING
LOSS OF PROFITS) OF ANY KIND.
It is the customer’s sole responsibility
to arrange for inspection and testing
of all products by qualified experts.
Reference to trade names used by other
companies is neither a recommendation
nor an endorsement of the corresponding product, and does not imply that
similar products could not be used.
phone +49 6151 18-1005
fax +49 6151 18-843570
[email protected]
www.rohacell.com
www.evonik.com
Evonik Foams Inc.
4375 Industrial Road
Theodore, AL 36582
USA
phone +1 866 764-6235
fax +1 866 764-6329
[email protected]
Evonik Specialty Chemicals
(Shanghai) Co., Ltd.
55 Chundong Road
Xinzhuang Industry Park
Shanghai 201108
China
phone +86 21 6119-3136
[email protected]
08/xy/000/en
Evonik Resource Efficiency GmbH
High Performance Polymers
Kirschenallee
64293 Darmstadt
Germany