By Touchstone Research Laboratory
CFOAM’s combination of thermal and physical properties make it an ideal material for a number of advanced thermal protection systems. CFOAM can insulate the underlying structure and components of a vehicle or device from excessive heat, while helping to define the outer surface and enhance structural integrity. CFOAM delivers unique high temperature properties. In the absence of oxygen, CFOAM materials can be heated to 3000°C without melting, while retaining its dimensional stability. Given its low coefficient of thermal expansion and relatively low modulus, it also affords high thermal-shock resistance.
Faster tooling. Stable geometry. Lower total cost. CFOAM enables a different approach to composite tooling. Instead of machining heavy metal and managing thermal inertia, engineers can build dimensionally stable, lightweight tools that machine easily, and scale without penalty. For carbon fiber layup, mandrels, and cure tools, CFOAM removes many of the constraints that have historically driven up cost and lead time. Why Engineers Choose CFOAM Composite Tooling with Clear Benefits Low CTE Where It Matters CFOAM maintains a coefficient of thermal expansion (CTE) near 2.8 ppm/°F, allowing tools to track composite parts closely through cure cycles. This reduces residual stress, improves dimensional accuracy, and minimizes iterative rework. Machinability Without Penalty CFOAM machines easily. Large billets can be bonded, shaped, and quickly modified. Design changes that would be cost-prohibitive in metal become routine. Lightweight at Scale At roughly 30 lbs/ft3, CFOAM tools are dramatically lighter than metal equivalents. This simplifies handling, reduces fixture requirements, and enables larger tool geometries without infrastructure changes. Cost Advantage Without Compromise Prototype tools have been demonstrated to have significant cost and lead time savings than Invar, while maintaining performance in real composite manufacturing environments. The Key Technical Advantage A Different Tooling Physics Conventional Tooling Dimensional Stability Thermal Responsiveness Manufacturability Most tooling materials force a tradeoff between dimensional stability, thermal responsiveness, and manufacturability. CFOAM Tooling Low CTE Low Density Machinable Structure CFOAM combines low CTE (dimensional control), low density (low thermal inertia), and machinable structure (fast iteration) without tradeoffs. For tooling programs limited by lead time constraints, rework, or modification cost, CFOAM is not simply a material substitution. It can change the cost, schedule, and flexibility profile of the entire tooling workflow. How CFOAM Tooling Is Built Proven Tool Construction Workflow Billet Formation Blocks are bonded into near-net shapes, enabling large tools without material constraints. Rough CNC Machining Geometry is cut efficiently with standard tooling. Surface Build-Up Carbon prepreg or a carbon filled epoxy resin are applied to create either a durable production style tool face, or a rapid prototype production option. Autoclave Cure The surface layer is consolidated under production-like conditions. Final Machining and Finishing Precision geometry is achieved, followed by sealing and polishing for release-ready surfaces. This hybrid approach combines the structural benefits of CFOAM with the surface performance of composite tooling systems. The prototype version is perfect for developmental programs as this tooling method is easily modifiable to support evolving engineering. It can then be "recycled" to convert it to production tooling by using the same base CFOAM material, then wrapping it with carbon prepreg adding durability with cost and lead time savings by repurposing the prototype version. Performance in Practice Validated in Composite Tooling Applications CFOAM has been used in hundreds of tooling builds, including complex geometries that would be difficult or costly in metal. - Large, multiple piece breakdown mandrels - Stable performance through repeated cure cycles - Reliable part release with standard surface treatments - Comparable surface hardness to traditional composite tooling systems CFOAM vs Traditional Tooling Materials Where CFOAM Wins: Performance Benefits CFOAM vs. Invar CFOAM vs. Aluminum CFOAM vs. Composite Tools (all-prepreg) CFOAM vs. Invar - Lower cost - Faster machining - Faster thermal response - Much lower weight - Faster lead times CFOAM vs. Aluminum - Lower CTE - Better dimensional stability across cure cycles CFOAM vs. Composite Tools (all-prepreg) - More stable core structure - Easier large-scale machining - Better repeatability in thick sections Design Flexibility Engineered, Not Just Selected CFOAM is not a single fixed material. Density, pore structure, and surface treatments can be tailored for each application. This allows engineers to optimize stiffness vs weight, permeability and vacuum integrity, surface integration strategies, and thermal response characteristics. The Key Perspective Tool performance is not just about the base foam. The surface system and integration method determine final performance. CFOAM enables more control over that system than traditional tooling materials. Practical Considerations A number of well-understood processes are already built into standard CFOAM tooling workflows. Such as surface sealing is required for vacuum and finish quality, and bonding and surfacing processes should be controlled for durability. Where CFOAM Fits Best CFOAM delivers the most value when: - Tools are large or complex - Iteration speed matters - Weight or handling is a constraint CFOAM is especially effective for: - Carbon fiber layup molds - Mandrels - Autoclave tooling - Prototype-to-production transitions Is CFOAM Composite Tooling Right For You? CFOAM is not just a substitute for metal tooling. It enables a different design and manufacturing approach. If your current tooling strategy is limited by cost, weight, or thermal performance, it's time to rethink these tooling constraints. CFOAM is worth evaluating early in the design process.
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CFOAM® HTC graphite foam – a graphitized, lightweight, open-cell carbon foam produced from mesophase pitch that features an exceptionally high thermal conductivity of about 100 W/m-K at room temperature with significant weight savings in comparison to copper (22 times lighter) and aluminum (7 times lighter). CFOAM HTC also has relatively high electrical conductivity, good strength, and a low coefficient of thermal expansion. It is easily machinable, chemically inert, corrosion free, and resistant to harsh environments and oxidation up to 400°C. With the infusion of a phase change material into its porosity, heat capacity can be greatly increased without a significant weight penalty. Manufactured at a scale, cost, and commercial output rate designed to penetrate already identified markets, CFOAM HTC graphite foam supports: - Thermal management heat sinks for application such as LED lighting, reducing weight and increasing life. - Lightweight and efficient heat exchangers for military applications. - Industrial heat exchangers for enhanced thermal heat transfer in single or multi-phase industrial heat exchanger products. - Electronics component cooling. - Automotive applications providing enhanced cooling in a smaller, lighter weight unit. - Solar, improving photovoltaic panel efficiency.
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CFOAM® — a non-combustible, lightweight, coal-based carbon foam exhibiting excellent mechanical and thermal properties – meets the growing demand for ultra-high performance engineering materials in the military, industrial, aerospace, and commercial product markets. CFOAM products enable technologies for a host of next-generation material systems and components, at times economically replacing conventional materials in existing systems to increase product life cycle and provide enhanced product performance properties. Available in substantial quantities in a variety of densities, form factors, and with material properties tailored to meet unique customer requirements, CFOAM uses conventional machining practices to produce intricate shapes and tight tolerances using carbide tooling and appropriate dust-handling systems. Resulting pieces can be attached to one another using readily available adhesives, allowing fabrication of large or complex composite tooling structures from smaller building blocks.
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CFOAM demonstrates some of the best fire, smoke, and toxicity properties of all insulating core materials available today. It is being tested as a fire-stop material in construction applications, as well as an insulator to prevent thermal runaway for lithium-ion batteries. CFOAM meets the “non-combustible” standard when tested in accordance with ISO 1182, as directed by the U.S. Coast Guard and the International Maritime Organization (IMO), whereas polymer-based foams do not, making them unsuitable for many marine applications. When tested under ASTM E1354, which measures composite material systems exposed to successive heat fluxes from 25-100 kW/m 2, CFOAM underwent no ignition, released no heat, and generated no smoke. CFOAM also is ideal for fire block and acoustic absorption applications in confined spaces with equipment enclosures, such as ships, trains, airplanes, buildings, and chemical plants, which have strict safety requirements.
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