New Zotek F OSU foam designed for extra rigidity and up to 70% weight reduction


Zotefoams has unveiled a new closed-cell OSU grade foam, Zotek F OSU XR, which was developed to reduce weight by as much as 70% in aircraft interior applications. The polyvinylidene fluoride (PVDF) foam is available in densities of 120kg/m³ and 150kg/m³. The company describes it as having an extra-rigid closed-cell cross-linked structure.

Complementing the flexible, semi-rigid and rigid grades already available in the Zotek F OSU range, the introduction of XR extends Zotefoams’ scope in aircraft interiors because XR has structural and semi-structural capabilities. Zotek F is already used for window seals, soft-touch trim, close-outs, insulation, carpet underlay and in environmental control systems. Zotefoams says Zotek F’s advantages include a light weight, ease of processing, frequent suitability to replace composite materials, and accordance with all relevant aviation standards, including for fire, smoke and toxicity (FST).

“With the introduction of the XR grade, we are extending the weight-saving benefits of the Zotek F OSU range to locations such as the interior of seat pods, stowage lockers, rigid armrests and tray tables, reducing weight by as much as 70% on a like-for-like basis,” said James Bridges, director of high-performance products at Zotefoams.

Grades of Zotek F can be laminated together to create a single material that is rigid on one side and soft/flexible on the other, and can be formed into curves and complex shapes, opening up opportunities for design teams. Zotefoams also points to the environmental benefits of weight savings, and the rigidity of Zotek F OSU XR, which it says can greatly reduce noise/vibrations when replacing thinner thermoplastics.

Zotek is manufactured in a process designed to produce foams with inherently low odour levels and a remarkably consistent closed-cell structure, characteristics that Zotefoams says make the foam exceptionally easy to fabricate via any number of processes including thermoforming, compression moulding, water jet, thermal bonding and lamination.

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Izzy has been part of the Business Jet Interiors International team since its second issue, and the editor since 2011. She also edits Auditoria and Railway Interiors International. Outside of work, Izzy is rediscovering her love of art by learning how to paint with watercolors.

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