Stop thinking 2 Dimensionally

Three-Dimensional structural cores

for fiber-composite components

For the non aviation industry, sandwich cores for fiber-composite components are mainly designed in flat structures. Daher Manufacturing’s innovative molding process now allows for the economic production of complex 3D structural cores for fiber-composite components. 

Our in-mold foaming process produces a 3D rigid foam core for the manufacturing of complex composite geometries. This process also allows metal parts, for example a threaded insert, to be directly intergraded into the foam core.

The materials used in our cores will have a strong impact on the performance of your sandwich constructions. Made of lightweight materials they are ideal for complex high-pressure RTM or wet-pressing processes, producing quick and efficient sandwich components.

Do not limit your design.  

Daher mfg is here to help make your 3D foam core for your next design a simple cost effective reality. 


Applications and Benefits


Daher Manufacturing Inc. develops and manufactures structural cores for the composites industry. Daher foam core materials are offered with variety of molded patterns and finishing, tailored to suit customer needs, budget or processing choices.

Foam core materials are utilised to deliver light weight, high strength, cost effective composite products with the performance specifications.

Sandwiching a lightweight core material between sheets of fiberglass can dramatically increase a laminate's stiffness without adding a lot of weight. Polyurethane foam core is cost-effective because the relatively low-cost core replaces more expensive composite reinforcement material and can be concurred with skins in one-shot processes.

Due to its bonding property and R-Value; polyurethane foam core is wildly used in automotive and bus industries. Foam cores are 100 percent in contact with the skin area, which could spreads the impact over a larger area. Daher foam core could bond to the laminates with or without adhesive in accordance with customers’ manufacturing specifications. Foam core material helps distribute loads and stresses on the skins, which makes a sandwich core panel an excellent design for absorbing impact stresses. A sandwich core panel’s compression strength prevents the laminate from bending or breaking. Furthermore, Cored panels also offer excellent heat insulation, fire proofing and vibration damping. Therefore, transit buses build with polyurethane foam core are much more energy efficient and environmental friendly.