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Foamlite® vehicle construction sheets
Vehicle construction sheets made of the lightweight plastic Foamlite®

Foamlite® vehicle construction sheets

Made of the lightweight plastic Foamlite® – for light and efficient commercial vehicles

Lightweight construction plays a key role in the development of modern commercial vehicles. The lower the weight, the lower the fuel consumption and environmental pollution for the same higher load capacity. We support the development of light and powerful commercial vehicles with our vehicle construction sheets made of Foamlite®

Foamlite® is a closed-pore foamed plastic that combines low weight with high mechanical stability. Vehicle construction sheets made of Foamlite®: 

  • Reduce the weight of your commercial vehicle 
  • Optimise the load capacity 
  • Are robust and durable 
Foamlite® - plastic vehicle construction sheets
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Lightweight and robust: Vehicle construction sheets made of the lightweight plastic, Foamlite®

Foamlite® vehicle construction sheets are available in many different formats, thicknesses, colours: 

  • Sheet thicknesses: 6 – 30 mm 
  • Widths: up to 2000 mm 
  • Lengths: According to customer needs, theoretically unlimited, no waste 
  • Surface: Surface grained on both sides with high scratch resistance or slip-resistant "cubic grain" surface 
Foamlite® - plastic vehicle construction sheets
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Foamlite® vehicle construction sheets: Available in many different sizes and colours; special sizes and custom colours possible on request

Application areas – Foamlite® vehicle construction sheets

Commercial vehicles: 

Our vehicle construction sheets made of Foamlite® are used in commercial vehicles such as: 

  • Transport vehicles, service vans, workshop vans, delivery vans 
  • Caravans, motor homes, camper vans 
  • Lorry trailers 
  • Horse trailers / horse transporters 

 

Structures and components:

Depending on the vehicle, Foamlite® vehicle construction sheets are used for structures and components including: 

  • Wall cladding 
  • Door cladding 
  • Interior cladding 
  • Flooring 
  • Partitions 
  • Shelving systems 
  • Doors with V-groove 

Properties – Foamlite® vehicle construction sheets

Lightweight

With their low weight, Foamlite® vehicle construction sheets make a contribution towards weight reduction, fuel efficiency and optimising the load capacity of your commercial vehicle. As a closed-pore foamed material, Foamlite® has a low density of just 0.65 g/cm³. Foamlite® is almost 30 percent lighter than comparable compact sheets.

Robust

Foamlite® vehicle construction sheets have high mechanical stability and scratch and shock resistance. Structures and components made of Foamlite® have a very long lifespan and a long-lasting, high-quality appearance. Compared with conventional PP honeycomb sheets, Foamlite® stands out thanks to its high stability combined with very good impact properties.

Low-maintenance – easy to clean

Foamlite® vehicle construction sheets are quick and easy to clean with commercially available cleaning agents and are very low-maintenance. Foamlite's® closed-pore foam core does not allow any material to penetrate the pores. Compared to conventional materials used in the market, Foamlite® offers many advantages when it comes to cleanliness and hygiene. Commercially available coated plywood sheets and textured, coated board can quickly become scratched and absorb moisture and dirt. This can lead to swelling and rotting. In commercially available honeycomb panels, dirt and moisture can remain in the honeycombs and form a culture medium for mould and bacteria.

High-quality surface

Foamlite® is available with a smooth or double-sided grained surface with high scratch resistance. Foamlite® vehicle construction sheets have a long-lasting, high-quality appearance.

Slip-resistant

Foamlite® vehicle construction sheets are available as a slip-resistant option with a "cubic grain" surface – tested in accordance with DIN 51130-R10. The slip-resistant surface prevents loads slipping in commercial vehicles. Fixed shelving systems for secure storage of small objects can also be made with the slip resistant Foamlite® vehicle construction sheets.

Good insulation properties

Air pockets in the foam core offer good thermal insulation and soundproofing. Vehicle construction sheets made of Foamlite® help to regulate the temperature in commercial vehicles.

Easy to work with

Foamlite® vehicle construction sheets can be worked on using conventional tools for wood and metal. The material is also easy to screw and rivet. We have extensive experience in the reliable mounting of our sheets using various fastening elements. Contact us. Foamlite® is also very easy to weld.

High resistance to UV radiation, weather and moisture

Foamlite® vehicle construction sheets include high UV and weather resistance and are also very resistant to moisture, which makes them suitable for long-term outdoor use

Application examples – Foamlite® vehicle construction sheets:

Foamlite® - plastic vehicle construction sheets in a caravan
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Floor panel made of a Foamlite® vehicle construction sheet in the storage compartment for gas bottles in a caravan - Photo Hobby
Foamlite® - plastic vehicle construction sheets in a camper van
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Shelving and worktops made of Foamlite® vehicle construction sheets for kitchen equipment in a camper van – Photo Cebotec
Foamlite® - plastic vehicle construction sheets in a service van
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Wall and door with V-groove made of Foamlite® vehicle construction sheets in a service van
Foamlite® - plastic vehicle construction sheets can be used in a lorry trailer
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Foamlite® vehicle construction sheets can be used in lorry trailers as wall cladding, for example
Foamlite® - plastic vehicle construction sheets in a horse trailer
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Foamlite® vehicle construction sheets in a horse trailer as door and wall cladding
Foamlite® wall cladding and door in a Sprinter transporter
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Wall cladding made of Foamlite® vehicle construction sheets in a Sprinter

Very high abrasion resistance

Surfaces in commercial vehicles must withstand high mechanical wear and tear in many areas over the long term. Tests in our in-house materials laboratory show that Foamlite® vehicle construction sheets have significantly higher abrasion resistance in comparison with tested conventional plywood (textured coated board) vehicle construction sheets. 

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Test parameters: Pressure: 150 N (0.66 MPa), Abrasion area: 15 x 15 mm, Sliding partner: stainless steel, Sliding direction: oscillating, duration: 90 minutes.
Vehicle construction sheets made of plastic – high abrasion resistance compared to plywood sheets / textured coated boards
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High abrasion resistance and no structural damage: In tests, the surface of Foamlite® (right) demonstrates significantly higher abrasion resistance than a conventional plywood/textured coated board (left)

Built-in hinge

Foamlite® has a "built-in" hinge. All that is required is a 90 degree milled V-notch. This means it is very easy to make doors with V-grooves, for example. This saves time in the manufacturing process and eliminates additional material costs for hinges, screws and rivets. 

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Foamlite® has a "built-in" hinge
Foamlite® - plastic vehicle construction sheets in a service van
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Door in a service van: Made of a Foamlite® vehicle construction sheet by simply milling a 90 degree V-notch.

Material – Foamlite®

We specially developed Foamlite®, a closed-pore foamed material, for applications in which construction materials need to be very low in weight while, at the same time, providing high mechanical stability. This opens up a wide range of possibilities in lightweight construction.

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The closed-pore, foamed structure makes Foamlite® sheets very lightweight

Technical data – Foamlite®

Properties 

Testing method 

 Unit 

Foamlite® 

Density 

DIN EN ISO 1183-1 

g/cm³ 

0.65 

Moisture absorption 

DIN EN ISO 62 

<0.1 

E-module 

DIN EN ISO 527 

MPa 

1100 

Shore hardness 

DIN EN ISO 868 

Scale D 

70 

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