The reduction of fossil fuels use and harmful CO2 emissions is a social challenge. Evonik Industries offers a variety of products to meet these goals. The PMI-based structural foam ROHACELL® saves enormous quantities of weight in car bodies.

Apart from energy-conscious driving and power train improvements, weight reduction in vehicles is the preferred method for saving fuel and reducing CO2 output. While the weight-reduction potential of conventional metal structures is approximately 10%, sandwiched composite structures made of ROHACELL® and CFRP can save over 50% of weight in the outer skin. This has been documented in studies involving a Golf V or the Lotus Exige. Based on the light weight demo model of the Lotus Exige, engineers were able to prove that the use of cover layers of approx. 0.7 mm CFRP and 2 mm ROHACELL® 71 IG-F noonly resulted in weight savings of 30% in the cladding, but also in a significant improvement of the inherent stiffness compared to a conventional CFRP structure. This is of particular interest for future urban vehicles or electrical cars, in which reduced weight will significantly contribute to downsizing the power train and improving range. 

Super sports vehicles and Formula 1 cars already use Boliden sandwich structures with ROHACELL for further gains in acceleration and handling because of lower weight.

• ROHACELL® can easily be shaped into 3D cores with thermoforming processes. Thanks to its high temperature resistance, the material allows for short cycle times over 100°C with advanced resin and inline coatings.

• ROHACELL® is free of FCKW, meets the heavy metal requirements of the End of Life Vehicles Directive 2000/53/EC and is listed in the IMDS.

• Studies of KTH in Stockholm, Cranfield University, and Lotus Engineering have documented the positive crash properties of ROHACELL®. Simulation values for the crash behaviour of ROHACELL® are available upon request.

Grades used in this industry


The majority of grades of Rohacell are with us ready to be processed, including IG, IG-F, HF, WF, RIMA & XT. We are very pleased to say we have the capability in most cases to offer next day delivery anywhere in the UK as standard.

Only a few niche grades are not held in stock and will be subject to a MOQ and lead time, but we will make you aware of this at the point of your order; we will always listen to your applications and help with alternate suggestions if you require material quickly and we don’t have it in stock.

With the highly popular and widely used grades IG, IG-F & HF, no order is too small! Other grades may be subject to a MOQ and this can vary depending on the grade. Please get in touch and we will gladly take time to discuss your exact requirements and tailor your purchase for you.

We are very proud of our state of the art factory, especially after our recent expansion and we have a number of machines that will cut and prepare Rohacell along with the skilled hands of our staff. Our plant includes a Horizontal Band Saw, Sanding Plant, Circular Saw & Laser Machine. This technology allows us to engineer Rohacell to within a guaranteed +/-0.5mm tolerance, or better still, +/-0.2mm on request. With our Laser machine, we can cut complex 2D shapes with minimal waste material.

Anything you require, on request. Our cutting plant means that we can machine Rohacell to any length, width and thickness within our largest sheet sizes of 2500mm x 1250mm as well as oversized 2600mm x 1300mm on request. Maximum dimensions & thickness can depend on the grade, so ask our advice. If you need a specific sized sheet with a thickness not listed, let us know and we will accommodate for you.

Beyond our ISO Standards, Industry and Quality Assurance certifications, our continued success if built on our core business values of delivering market leading products coupled with first class customer care, from our team of dedicated and passionate individuals. We take time to listen to your needs, however big or small those are and work hard to maintain a rapport with our clients. Our facilities in Norwich mean we can cater for purchases from all over the world. We are impartial, independent and confidential; we are Emkay.

Get in touch with us on the number or email at the top of our webpage. In office hours, we have a friendly team at the end of the phone who have a vast combined expertise with Rohacell and if we don’t know the answer, we will know where to find it for you! We will talk you through the order, payment and delivery process so that you stay fully in the loop.