As the economy grows, people are becoming alarmed about the increased rate of deforestation and greenhouse gas emissions, and the demand for lightweight materials and sustainable alternatives to wood, aluminum, copper, concrete, polystyrene, polypropylene, and others has increased significantly. One of these promising eco-friendly alternatives is PVC foam boards/sheets. But what exactly is PVC foam? PVC foam is a lightweight, rigid form of expanded polyvinyl chloride (PVC). It can be manufactured depending on its density, either in open-cell or closed-cell, having the latter being dense. These materials are known for their excellent strength, durability, and easy workability, thus being found to meet uncountable indoor and outdoor application needs, making them one of the most popular commodity thermoplastics.
PVC resins are heated and mixed with additives such as foaming agents, stabilizers, fillers, etc., to make the raw material of PVC foam. This material is then cooled and stored. Using heat, friction, and shear, the raw material is extruded to form foam. Most foaming agents heat up and emit carbon dioxide or nitrogen gas, producing cavities. After entering the mold, materials are measured and adjusted, and the sheet's edges are cut and sawn. The additives and process monitoring significantly affect the end product's quality. At APM, we commit to the sustainability and high-end quality of the process, from locally sourced raw materials and state-of-the-art manufacturing processes down to the packaging and on-time delivery to the end users.
Hundreds of commercial applications of these materials range from indoor and outdoor uses. These applications include ceiling and roofing panels, door and window panels, or even thermal and noise insulation purposes for roofs, ceilings, walls, and partitions for private houses, commercial buildings such as restaurants, stadiums, shopping malls, office buildings, warehouses, and storage rooms, industrial construction, and infrastructure. Other applications span doors, ceiling and roofing panels, partitions, sidewalls, and seat bottoms for vehicles such as cars, buses, trucks, trains, yachts, and cruise ships. Due to its durability and lightweight properties, PVC foam board can also be used for indoor and outdoor furniture such as tables, benches, chairs, walking closets, and drawers. Due to its weather resistance properties, outdoor use includes its application as shield walls and partitions for wind and storm. Also, they are widely used for advertisement and display boards. PVC foam boards are used for consumer articles and goods such as snowboards, skis, football helmets, and leisure items such as inflatable beach toys and paddling pools. Aside from commercial applications, industrial sectors, such as marine, find their uses in nacelles, decking, floorings, and interior superstructures. Due to its light weight, it is employed in the aircraft interior, fuselage and wind components, kitchen trolleys, galleys, and cargo containers in the aerospace industry. Moreover, it is also used for wind turbine construction, specifically its rotor blades, nacelles, covers, and casings.
The following processing techniques are employed to manufacture your desired components, such as furniture, door and ceiling panels, etc.
Compression Molding: PVC foam sheet is put in a temperature-controlled chamber and then reshaped under pressure using a hydraulic press.
Thermoforming: Thermoforming is a process that involves heating the PVC foam sheet until it softens. Then the sheet is put in and stretched across the mold and shaped.
PVC foam boards and sheets also can be cross-linked with other polymers, glass, or ceramic fibers to make composite materials because of their excellent compatibility with multiple resins. These processing techniques can form sandwich-structured composites, e.g., honeycomb structures which provide material with extremely low density and high specific strength. Some of these techniques include:
Lamination: Lamination is a way of making a composite system that improves stability, appearance, and strength by stacking two or more materials in multiple layers. It can be done manually with adhesive bonding (hand lamination) or by spraying resin (spray-up) and chopped fiber using a handgun.
Prepreg Processing: Prepreg is a term for composite materials that are "pre-impregnated" with resins and then hardened, like carbon, graphite, or glass fibers. This pre-impregnation can be done via heat, solvent, or resin filming.
PVC foam boards offer many advantages compared to their substitutes, such as wood, aluminum, concrete, metallics, or polystyrene foam. They have superior mechanical and physical properties, such as exceptional strength, excellent durability, tremendous impact, and shock resistance, and are lightweight. Their densities can be easily customized and adjusted depending on the application. They are known for their thermally stable properties, thus utilized as insulation panels, and are even fire resistant. They are robust materials known for outdoor applications because of their excellent corrosion, weather, UV, and chemical resistance properties. Moreover, unlike wood and other metallic substitutes, they have a very low water absorption rate, do not rot, mold, or mildew, and are very easy to install and operate. Due to their easy workability and compatibility, they can be painted, laminated, or coated with thermoset resins and adhesives. Moreover, these foam boards are eco-friendly and 100% recyclable. Due to its adjustable cost, it's becoming the finest alternative for household and industrial applications.
At APM, we have a large selection of high-quality PVC foam boards and sheets exclusively manufactured in the USA and Italy. Our raw materials and additives are sourced locally; therefore, ultimate quality is guaranteed. Our products are produced sustainably and 100% recyclable. The following PVC foam boards and sheets are available in our inventory.
For additional information and technical specifications [TDS and MSDS], please contact us. We help you select the best material for your project and application. We also complete custom production and will meet your specification requirements.
We are strongly committed to the absolute quality and performance of our PVC foam sheets and boards. Our materials processing is guaranteed 100% sustainable, modern, and state-of-the-art in alignment with international regulatory compliance certifications, including ISO, EPD, and REACH compliant. We offer competitive pricing and other benefits over other manufacturers and suppliers, including replacement of material supply at no extra cost, free shipping on qualified order volumes, on-time delivery to meet target demand, and free technical support and consultancy. Moreover, we offer custom production and processing based on your manufacturing needs. Our products are exclusively manufactured in the USA and Italy, with our raw materials and additive sourced locally. We commit to our responsibility to sustainable manufacturing with no toxic chemicals used in our products or released during the lifecycle, which can be harmful to other human and living organisms, and we continue to reduce our CO2 and carbon emissions in the process.
Contact us via email or phone or through our website for your PVC foam sheets and boards need.
Jay Mondal (CEO/CTO), PhD
Phone: +1 929 476 3870