Raw Material Preparation: The process begins with the preparation of raw materials, which may include thermoplastic or thermosetting resin systems, additives, blowing agents, and reinforcing materials. These materials are carefully selected and measured to meet the desired properties and specifications of the foam core.

Blending and Mixing: The raw materials are blended and mixed to form a homogeneous mixture. The mixing process ensures that the resin system is evenly distributed throughout the material.

Foaming: To create the foam structure, a blowing agent is introduced into the mixture. The blowing agent generates gas bubbles within the material, resulting in the characteristic foam structure. The choice of blowing agent and its activation method (e.g., chemical or physical) can vary depending on the desired characteristics of the foam.

Curing or Polymerization: For thermosetting resins, the foam core material is typically subjected to a curing process, such as heat and/or pressure, to polymerize the resin and set the foam's structure. This step may also involve the use of molds or presses to shape the foam core into the desired form.

Cooling and Solidification: After curing or polymerization, the foam core is cooled and allowed to solidify. This helps stabilize the structure and ensures that it maintains its desired shape.

Cutting and Shaping: Once solidified, the foam core can be cut and shaped into the desired dimensions and forms. Precision cutting machinery or tools are used to achieve the required shapes and sizes.

Quality Control: Throughout the manufacturing process, quality control measures are implemented to ensure that the foam core material meets the specified standards and requirements. This may involve testing for properties like density, cell structure, strength, and thermal properties.

Packaging and Distribution: After passing quality control checks, the foam core material is packaged and prepared for distribution to customers in the aerospace and other industries.

It's important to note that the specific manufacturing process for Cascell® RS or any foam core material may vary depending on the manufacturer's proprietary techniques and formulations. Manufacturers may also employ additional steps or modifications to the process to achieve particular properties or characteristics that are unique to their product.