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Lightweight Structural Materials for Aerospace OEM Manufacturing

GracoRoberts supplies lightweight structural materials that let aerospace OEMs reduce weight without sacrificing mechanical performance. Syntactic epoxies, foaming core splice adhesives, and microsphere-filled compounds fill, stabilize, and join composite sandwich structures at a fraction of the density of solid adhesive, directly supporting the fuel-efficiency and payload targets driving new aircraft design.

Our portfolio includes Huntsman Epocast syntactics, Solvay and Loctite foaming films, and microsphere fillers, many qualified to Boeing BMS and platform specifications.

Lightweight Material Types

Epoxy Syntactic Compounds

Microsphere-filled epoxies for low-density core fill, edge fill, and potting. Products include the Epocast syntactic range, Epocast 1617, Epocast 1618, and Epocast 1652. See our full epoxy syntactic systems category for the complete range.

Foaming Core Splice Adhesives

Expanding film and foam adhesives for splicing and edge-filling honeycomb core. Products include Loctite EF 562 foaming core splice adhesive and Solvay FM 410-1 foaming film.

Laminating Systems and Microsphere Fillers

Laminating resins and bulk microspheres for lightweight layup and custom fill. Products include Epocast 50-A1 laminating system and Phenoset microspheres.

wing of an airplane

Selecting Lightweight Structural Materials

OEM engineers balance weight against mechanical and processing requirements:

  • Density versus strength - lower density reduces weight but trades compressive strength; match to the structural requirement
  • Application format - liquid syntactics for repair and complex geometry, films for high-volume core splicing
  • Specification - Boeing BMS, Sikorsky SS, or platform qualification on the approved list
  • Processing - cure schedule, out-life, and FST (flame, smoke, toxicity) requirements for interior applications

These materials work alongside the load-bearing adhesives on our structural bonding systems page and follow the controlled-material workflow described under spec-driven adhesives and sealants.

Talk to our team about lightweight material selection and qualification.

Frequently Asked Questions

What is a syntactic epoxy and why is it lightweight?

A syntactic epoxy is a resin filled with hollow glass or phenolic microspheres. The microspheres displace resin volume with air, reducing cured density while maintaining compressive strength, making syntactics ideal for lightweight core fill, edge fill, and potting in composite structures.

What is a foaming core splice adhesive?

A foaming core splice adhesive is a film or compound that expands on cure to fill and join sections of honeycomb core. It bonds adjacent core pieces and fills edge voids in sandwich panels with minimal added weight.

Are lightweight structural materials qualified to Boeing specifications?

Many are. Epocast 1617, 1618, and 1652 and Epocast 50-A1 laminating systems carry Boeing BMS, Sikorsky SS, or platform qualifications. Confirm current status against the product data sheet and your program approval list.

What are microspheres used for in aerospace materials?

Hollow microspheres are added to resins to reduce density and create syntactic compounds, or supplied in bulk for custom lightweight formulations and fill applications. Phenoset and glass microspheres are common fillers in aerospace syntactics.