This paper presents a novel constrained foaming process to produce microcellular panels. A systematic study of various process variables is conducted using a two-stage, sliding-level design of experiment approach. The resulting microcellular sheets have thicknesses in the 5 – 15 mm range and densities reductions as low as 92%. It is shown that an unfoamed integral skin of desired thickness can be produced with a microcellular core at various densities. These microcellular panels are envisioned for use in advanced panel systems and sandwich structures, such as in housing construction and other load-bearing applications.
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