When producing lightweight PET sandwich panels, reducing density by 5% to save weight – what performance penalty can be expected?

Foam core compressive strength follows a power law σ ∝ ρ^(1.5–2.0), and shear modulus G ∝ ρ^(1.8–2.2). For example, reducing density from 100 kg/m³ to 95 kg/m³ (5% weight reduction) results in approximately 9–10% lower compressive strength and 8–11% lower shear modulus. More critically, the peak fatigue stress decreases about 12%, forcing a reduction in design allowable stress. Additionally, lower density PET foam has coarser cell structure, reducing the bonding contact area with facings and decreasing peel strength by about 5–7%. Therefore, the benefit of weight reduction must be carefully balanced; a better approach is to optimize cell morphology (finer, more uniform closed cells) to improve mechanical properties at the same density.

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When producing lightweight PET sandwich panels, reducing density by 5% to save weight – what performance penalty can be expected?

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