Rigid Cellular PVC

Auroralite™ compounds are designed to be light weight and dimensionally stable in a variety of applications.

Auroralite™ TPE, TPO and flexible PVC cellular foam are a series of expandable compounds to be used in a variety of applications. These include footwear and other lightweight injection molding applications.

Auroralite™ rigid PVC cellular foam includes powder compounds that generate lightweight, low-density profiles ideal for interior/exterior trim work, windows, garage doors, weather seals, decking, railing, slat wall and much more. These PVC cellular foam extrusion grade compounds can be used as a lightweight wood replacement that can be easily cut, routed and shaped just like real wood, with the added benefit of being rot, warp and crack resistant. Because of its reduced density (lighter weight), processors are able to make more parts with less compound.

Aurora Material Solutions Adds Value

There is a common misconception that processing cellular foam is difficult. It is really quite easy, and Aurora Material Solutions can help. We bring years of experience and technical knowledge to the process and can help you achieve your goals using the best quality compounds. Bring us in to the process early, so we can help you develop a system that perfectly suits your needs.

Extrusion Processes – Free Foam vs. Celuka (‘sell-oo-ka)

There are two methods of producing cellular rigid PVC parts: “free foaming” and Celuka processing. In the free-foam method, the cellular foam PVC melt expands freely after leaving the die head, prior to entering the calibrator, which is separated from the die. The die opening is smaller than the calibrator opening, allowing for the foam to swell into the calibrator, creating an even foam density distribution across its thickness and resulting in minimal skin formation.

The Celuka process utilizes a mandrel inside the die and typically there is little space between the die and calibrator. The mandrel generates a hollow section as the profile exits the die that encourages the foaming action to fill this hollow by inward foaming. The cooling of the surfaces that come into contact with the calibrator walls creates a very strong, glossy outer skin on the part’s surface while inwardly filling the foam part.

Why Use Auroralite™ Compounds?

Aurora Material Solutions has decades of experience in rigid PVC compound manufacturing and processing. We will partner with your company to assess your needs and select materials. Our experts can also provide advice on appropriate extrusion processing equipment and conditions that meet your expectations.

Our Auroralite™ compounds are available in a broad range of densities to meet the architectural and structural requirements of the desired application. Auroralite™ compounds possess excellent uniform cell structure which drives better physical properties. We even have hybrid free-foam/Celuka PVC cellular compounds that can be customized to meet your needs. When you put our experience to work for you, the cellular PVC process becomes quick and easy.

Benefits of Rigid Cellular PVC

  • Ease of processing
  • Can run on a single- or twin-screw extruder
  • Less dense (lighter) than wood
  • Can be painted or premixed with color
  • Rot-resistant
  • Fire-retardant
  • Pest-resistant
  • Can be capstocked
  • Easy to install
  • Variety of densities available based on structural requirements

Our experienced R&D team will work with you to develop a formulation that will meet your specific application needs. Our goal is to provide the highest quality products and the best customer service in the industry. We work closely with you throughout the process to meet your specific needs, from determining the formulation for the job, to assistance with colors and compound matching. Aurora Material Solutions strives to be our customers’ “first choice” in polymer compound solutions.