FST OSU & Low Heat Release Foam - Aerospace Interior Foam | General Plastics
phone icon
phone icon
Local: (800) 806.6051
phone icon
International: (253) 473.5000
Request a quote

FST/OSU Aerospace Foam


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 FR-3800 FST Panel Configuration


Tedlar / CYCOM2265 / CYCOM2265 / AX2150 / 380445256177
Tedlar / CYCOM2265 / CYCOM2265 / AX2150 / 380883940181
CYCOM 2265 / .005″ Aluminum Foil / CYCOM2265 / AX2150 / 380445159112
CYCOM 2265 / .005″ Aluminum Foil / CYCOM2265 / AX2150 / 380884351110

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 as a high density and low density foam (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″
  • 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
  • Max use temperature of 280°F (138°C)
Ask For More Info

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


ProductsDensity (lbs/ft3)Height (in)Width (in)Length (in)Request a Quote
FR-3803 FST3284896Quote »
FR-3804 FST4284896Quote »
FR-3808 FST8244896Quote »
FR-3830 FST30122496Quote »
FR-3840 FST401018100Quote »
ProductsDensity (kg/m3)Height (cm)Width (cm)Length (cm)Request a Quote
FR-3803 FST4871122244Quote »
FR-3804 FST6471122244Quote »
FR-3808 FST12861122244Quote »
FR-3830 FST4813061244Quote »
FR-3840 FST6412546254Quote »

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

Related Resources

Resource Image

Case Applications

Filling the Need for Consistent, Reliable and Cost-Effective Composite Core Material in Sandwich Panels

Read More
Resource Image

Technical Papers

Composite Core: Factors to Consider When Choosing Core Material for Your Application

Read More
Resource Image


General Plastics’ Aerospace-Grade Core Materials and Built-to-Print Polyurethane Parts For the Business Aviation Industry

Read More
Resource Image


Looking to the Future: National Composites Week 2019

Read More