6mm High Density DIY XPS Foam Board for Door Core

Our high-quality Door Intermediate Material XPS Foam Board is meticulously designed to meet the diverse needs of modern door manufacturing. The board's structure is engineered with precision, featuring a uniform and dense cellular composition. This unique cellular structure is achieved through advanced extrusion processes, ensuring consistent quality throughout the board.

The surface of the XPS foam board is smooth and flat, which not only provides an ideal base for further processing but also contributes to the overall aesthetics of the door. It can be easily bonded to other materials such as wood, metal, or plastic, enhancing the door's structural integrity and performance. The edges of the board are carefully cut to ensure a perfect fit within the door frame, minimizing any potential gaps that could lead to heat loss or air leakage.

To enhance its functionality, our XPS foam board can be customized in terms of thickness. We offer a wide range of thickness options to accommodate different door designs and insulation requirements. Whether it's a thin layer for lightweight doors or a thicker one for doors that demand higher insulation performance, we can tailor the board to meet your specific needs. Additionally, the board can be pre-treated with special coatings or additives to improve its resistance to moisture, fire, or other environmental factors.

DIY-Friendly Handling

At only 6mm thick and weighing 4.5-5.2 kg per 1200x2400mm sheet, this foam board is easy to transport, maneuver, and cut with standard household tools including utility knives, scissors, and jigsaws. It produces clean cuts without crumbling or generating hazardous dust, reducing cleanup time and respiratory risks during DIY projects.

High Structural Rigidity

Despite its thin profile, the high-density formulation provides a flexural strength of ≥10 MPa, making it suitable for door core applications where rigidity is essential. It resists bending and warping under normal use, maintaining door flatness even in humid environments. The material’s high impact resistance prevents dents from accidental bumps, ensuring long-term appearance.

Thermal and Acoustic Enhancement

This XPS foam board offers a thermal conductivity of ≤0.033 W/(m·K), providing effective insulation that reduces heat loss through doors by up to 30% when installed in hollow door cores. Its dense cell structure also improves sound attenuation, reducing airborne noise transmission by up to 15 dB, enhancing privacy in bedrooms, home offices, and workshops.

Versatile Compatibility

The smooth surface accepts various adhesives, paints, and veneers, with excellent bonding strength (>0.3 N/mm²) to wood, metal, and plastic substrates. It is compatible with common door materials including plywood, MDF, and composite panels, allowing seamless integration into existing door assemblies. The material is resistant to common household chemicals, ensuring compatibility with paints and finishes.

Our high-quality Door Intermediate Material XPS Foam Board is widely used in a variety of door applications. In residential buildings, it is an ideal choice for interior and exterior doors. For exterior doors, it provides excellent thermal insulation, protecting the home from the elements and reducing energy costs. For interior doors, it can help to reduce noise transmission, creating a more peaceful and comfortable living environment.

In commercial buildings, such as offices, hotels, and retail stores, our XPS foam board is used in the construction of doors to enhance their performance. It helps to maintain a stable indoor temperature, improve energy efficiency, and provide a more comfortable working or shopping environment for occupants. Additionally, the board's durability and resistance to moisture and chemicals make it suitable for use in commercial settings where doors are subject to frequent use and exposure to various environmental factors.

Our XPS foam board is also used in the manufacturing of specialized doors, such as fire-rated doors, soundproof doors, and insulated garage doors. In these applications, the board's unique properties, such as its thermal insulation, fire resistance, and sound absorption, play a crucial role in meeting the specific requirements of the doors.

Q1: Can the XPS foam board be easily cut to fit different door sizes?

A: Yes, our XPS foam board can be easily cut using standard cutting tools such as a utility knife or a saw. Its uniform structure and lightweight nature make it simple to shape and customize to fit the specific dimensions of different doors. However, it is important to use sharp tools and follow proper safety precautions when cutting the board to ensure a clean and precise cut.

Q2: How long does the XPS foam board last in a door application?

A: Under normal conditions, our XPS foam board can have a long lifespan of 20 to 30 years or even more in a door application. The board's resistance to moisture, chemicals, and physical damage, along with its durable construction, contributes to its longevity. However, factors such as the quality of installation, the environmental conditions, and the level of usage may affect its lifespan. Regular inspection and maintenance can help to extend the life of the board.

Q3: Is the XPS foam board safe for use in residential doors?

A: Yes, our XPS foam board is safe for use in residential doors. The materials used in its production are carefully selected to meet strict safety standards. The board does not release any harmful substances or odors that could pose a risk to human health. Additionally, its fire resistance and other safety features make it a reliable choice for residential door applications.

Q4: Can the XPS foam board be recycled at the end of its useful life?

A: Yes, our XPS foam board is recyclable. At the end of its useful life, it can be collected and processed for recycling. Recycling XPS foam helps to reduce waste and conserve resources. We encourage our customers to recycle the board in accordance with local recycling regulations and practices.