Using the FR-3800 FST Core as an Alternative to Thermoplastics

The FR-3800 FST foam core is a halogen-free polyurethane-based foam core material that complies with fire, smoke and toxicity (FST) requirements, and Ohio State University (OSU) 65/65 heat release standards for aerospace applications. It is also compliant with the European Union’s REACH regulation. The FR-3800 FST foam core, used in conjunction with other materials, reduces costs and enhances aesthetics while meeting fire safety requirements. It is available in a sheet thickness of up to 28 inches and also in a wide range of densities (3 – 40 pcf). Custom sizes and thickness are also available. This series is considered to be an exceptional core material alternative to honeycomb and thermoplastics for core and structural FST applications.

. . . . . . .
lbs./ft3 3 4 8 18 30 40
kg./m3 48 64 128 288 480 640


FR-3800 FST Foam Features and Benefits

The key features and benefits of the FR-3800 FST foam are as follows:

  • Sheet thickness up to 28"
  • Meets OSU 65/65 heat release standards
  • Withstands process temperatures up to 310 °F (154 °C)
  • Passes Fire/Smoke/Toxicity (FST) requirements
  • High strength-to-weight ratio from crosslinked structure
  • Thermoformable into simple curves
  • Shapes easily with common machining methods
  • Resistant to most solvents and chemicals
  • Bonds well with composite skins
  • No edge-closing or filling needed
  • Will not support fungal growth
  • Alternative to thermoplastics and honeycomb in FST applications

FST Foam Core Applications

The main applications of the FR-3800 FST foam include:

  • First-class seating pods
  • Sandwich core:
    • Door panels
    • Floor ramps
    • Seat backs
    • Tray tables
    • Ceiling and wall panels
    • Passenger cabin class dividers
    • Hard points in composite panels
  • Edge closeouts
  • Support/shim pieces
  • Lightweight flyaway parts

Sizing Chart


Products Density (lbs/ft3) Height Width Length
FR-3803 FST 3 28 48 96
FR-3804 FST 4 28 48 96
FR-3808 FST 8 24 48 96
FR-3818 FST 18 18 18 100
FR-3830 FST 30 12 24 96
FR-3840 FST 40 10 18 100


Shown are maximum standard stock sizes based on density. Custom sizes are available. Cut sizes are available from 0.125 inches (3.175 mm) up to standard stock heights as listed above.

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