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FST/OSU Aerospace Foam


LAST-A-FOAM® FR-3800 FST

The LAST-A-FOAM® FR-3800 FST is a halogen-free polyurethane-based foam core material which complies with fire, smoke and toxicity (FST) requirements, and Ohio State University (OSU) 65/65 heat release standards for applications such as aerospace interiors. It is also compliant with the European Union’s REACH regulation. Used in conjunction with other materials, FR-3800 FST foam core helps improve aesthetics and reduces costs while meeting fire safety requirements. In most cases, these requirements apply to ceiling and wall panels or structures that cover large surface areas within the aircraft. This series is an excellent alternative to thermoplastics foams and honeycomb for core and structural applications.

The panel configurations described below meet FST/OSU requirements which are defined as material testing below specified limits for peak heat release, total heat release, smoke density and toxicity. The table shows the average values obtained for heat release and smoke density for each respective configuration along with the specified limits shown in the top row.

Download the FR-3800 FST Panel Configuration PDF.

CONFIGURATION FR-3800 FST DENSITY (lbs/ft3) HR PEAK (kW/m2) HR TOTAL (kW/m2) SMOKE DENSITY
FST/OSU REQUIREMENTS <65 <65 <200
Tedlar / CYCOM2265 / CYCOM2265 / AX2150 / 3804 4 52 56 177
Tedlar / CYCOM2265 / CYCOM2265 / AX2150 / 3808 8 39 40 181
Tedlar / CYCOM 2265 / CYCOM2265 / AX2150 / 3820 20 41 34 150
CYCOM 2265 / .005″ Aluminum Foil / CYCOM2265 / AX2150 / 3804 4 51 59 112
CYCOM 2265 / .005″ Aluminum Foil / CYCOM2265 / AX2150 / 3808 8 43 51 110
CYCOM 2265 / .005″ Aluminum Foil / CYCOM2265 / AX2150 / 3820 20 49 48 132

Table 1: Configurations are shown as layers upon its respective 3800 core material, which is 1/2″ thick. The opposing side of the core can either be the same as that shown (symmetrical), or consist of 38XX/CYCOM 2265/CYCOM 2265. CYCOM 2265 is a 7781 glass phenolic resin prepreg meeting BMS8-226, and AX-2150 is a low heat release modified phenolic adhesive film.

FR-3800 FST is available in a wide range of densities (3 – 40 pcf), and sheet thickness of up to 28 inches. Custom sizes and thickness are also available. 

FR-3800 FST Foam Features and Benefits

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

FST Foam Core Applications

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

Sizing Chart

ENGLISH UNITS

Products Density (lbs/ft3) Height (in) Width (in) Length (in)
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

METRIC UNITS

Products Density (kg/m3) Height (cm) Width (cm) Length (cm)
FR-3803 FST 48 71 122 244
FR-3804 FST 64 71 122 244
FR-3808 FST 128 61 122 244
FR-3818 FST 288 46 46 254
FR-3830 FST 481 30 61 244
FR-3840 FST 641 25 46 254

Shown are maximum standard 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.