OptiForm X2L ®  The new XLarge and Light plug assist system


OptiForm X2L is a syntactic foam developed for plug assists and pushers used with positive or negative tooling in heavy gauge thermoforming applications.

It combines a two part system: OptiForm thermoplastic syntactic foam with a core of hollow macrospheres in order to reduce up to 40% of weight.

The core and the casting part will be specially designed according to your specific needs keeping dimensional stability and mechanical properties.

For PP, PET Thermoformed parts:

  • Productivity + 5 % to 35 %
  • Reduce Thickness -3 to 15 %

Technical Properties


Density(ρ)                                                                     44 – 48 lb/ft³                                             710 – 770 kg/m3
Thermal Conductivity(k)                                0.086 BTU /hr-ft-°F                                      0.17 W/m°K
Specific Heat (Cp) per mass                             0.43 BTU/(lb·°F)                                         1.80 kJ/(kg·°C)
Coef. of Thermal Expansion (CTE)              33 x 10-6 in/in/°F                                     60 x 10-6 m/m/°C
Compressive Strength                                              9,700 psi                                                          67 Mpa
Compressive Modulus                                               298 Ksi                                                            2.05 Gpa
Service Temperature                                                    356°F                                                               180 °C

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Our products are designed to eliminate dust from toolmakers workshop. Machining and finishing in a dust-free environment with OptiForm.