Why do some XPS sandwich panels develop an "orange peel" texture on the surface? Does it affect performance?

Orange peel results from uneven melt surface tension as XPS exits the die, typically related to the temperature and surface roughness of the cooling sizing rolls. Orange peel depth <0.1mm is only an aesthetic defect and does not affect bonding strength. However, if depth exceeds 0.3mm with sharp valleys, adhesive can trap air bubbles, leading to voids and potential delamination under dynamic loading. Acceptable standards (DIN EN 13164) specify that for visible-face sandwich panels, surface roughness Ra should be ≤25μm. High-quality XPS suppliers use polished sizing rolls or online sanding to remove the surface skin.

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Why do some XPS sandwich panels develop an “orange peel” texture on the surface? Does it affect performance?

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