XPS Foam Sandwich Panels

XPS foam sandwich panels are widely used composite panels, valued for the outstanding performance of their XPS (extruded polystyrene) closed-cell foam core across multiple parameters. These panels are widely used across various industries.

TOPOLO is a professional composite sandwich panel manufacturer. Here we provide you with a series of composite solutions. We customize width, thickness, length, skin, core, color, surface treatment and more for your product. In addition, we also provide CNC machining services for your plates, which greatly reduces your reprocessing workload.

Product Introduction

XPS foam sandwich panels are one of the most popular foam sandwich composite panels, which is a typical representative material combining strength and lightweight. Its core material is closed-cell extruded polystyrene foam, and its skin material has a variety of options (fiberglass, aluminum, wood, steel, plastic, etc.). The skin and core are bonded together by vacuum compression molding using high-quality polyurethane glue as an adhesive.

Specifications

Skin Material	FRP (GRP, fiberglass reinforced plastic ) sheet
	CFRT (Continuous fiber-reinforced thermoplastic) sheet
	Aluminum sheet
	Steel sheet (Galvalume steel – GL or prepainted galvalume steel – PPGL)
	HPL (High-pressure Laminate) sheet
	PET(polyethylene terephthalate ), PVC (polyvinyl chloride) sheet
	Plywood
Core Material	XPS（extruded polystyrene) Foam Board. (Density: 30~50kg/m³)
Width	≤3.2m
Total Thickness	10-120mm
Length	≤13.5m
Skin Color	RAL Color Series
Processing	CNC Machining, Embedded Structure

XPS Foam Board

XPS (extruded polystyrene), is made of polystyrene resin as raw material plus other auxiliary materials and polymers, while heating and injecting a catalyst, and then extruded to form a rigid foam plastic board. It has a very low Hygroscopicity (almost no water absorption), low thermal conductivity, and high compression resistance. Its surface is uniform and flat, and the interior is a completely closed cell, so it has the characteristics of high-pressure resistance, lightweight, non-absorbent, airtight, wear-resistant, and non-degradable.

Physical Properties of XPS Foam Core

Items	Unit	Value
Density	Kg/m3	35~55
Compression Strength	Mpa	0.1~1
Closed Cell Rate	%	≥99
Thermal Conductivity	W/m·K	0.024~0.034
Water Absorption	%	≤1
Operating Temperature	℃	-50~+80

XPS Foam Sandwich Panels are Available in Different Skin at TOPOLO

Due to the excellent compatibility between XPS foam and adhesive systems, XPS foam bonds effectively with a wide range of existing facing materials without delamination.

FRP + XPS

• FRP sheet is a composite containing resin and fiberglass, which has the advantages of high strength, rigidity, lightweight, corrosion resistance, waterproof, and electrical insulation.

CFRT + XPS

• CFRT is an advanced version of FRP, with continuous fibers and higher strength. 

Aluminum + XPS

• The advantages of aluminum sheets lie in the fact that aluminum is the lightest metal; it does not rust and is fully recyclable.

Coated Steel + XPS

• Coated steel (GI, GL, PPG, IPPGL) offers excellent structural strength.

Advanced Processing for Sandwich Panels

Sandwich panel technology goes beyond the basic “skin-core-skin” configuration. To meet the rigorous demands of various industries—such as the need for larger dimensions and superior structural strength—integrating internal embedded frame systems is a key measure for enhancing the panel’s structural performance.

Discover TOPOLO Advanced One-Piece Composite Technology

Scientific process control enables a high-strength bond between the skin and the core material.

Precise Adhesive Control

• Precision adhesive formulation and strict dosage control are employed. Insufficient adhesive compromises bond strength, while excessive adhesive can lead to panel shrinkage, warping, or deformation over time.

Vacuum High-Pressure Lamination

• The panels undergo integrated composite pressing within a sealed, high-pressure vacuum environment. This ensures the adhesive fully permeates and cures completely, resulting in a stable, reliable composite structure with exceptional durability, flatness, and service life.

High-Precision Machining

We provide customers with high-quality sandwich panels that are ready for direct installation, improving installation efficiency while reducing on-site processing costs. Advanced CNC machining equipment is used to precisely cut, drill, trim, and shape raw sandwich panels, ensuring they meet the required design dimensions and structural specifications. Through strict process control and comprehensive quality inspections, products within the same batch achieve excellent dimensional accuracy and consistency.

Typical Applications of XPS Foam Sandwich Panels

• XPS sandwich panels are the most popular RV body panels. Such as wall panels, floors, and roof panels for caravans, travel trailers, campers, mobile villas, etc.

• It is suitable for storage and transportation of medicines, fresh meat, vegetables, cold drinks, fruits, etc. It is one of the most important materials for refrigerated truck bodies and cold rooms.

• XPS sandwich panels are widely used in buildings that require heat insulation, such as temporary houses, mobile villas, mobile toilets, etc., which greatly reduce the cost of building construction.

• XPS sandwich panels can be used as wall panels, weather panels, floors, partitions, etc. inside yachts.