Description
Blu-Float Solid Buoyancy Foam is intended for customers who need more than basic flotation material. It is suitable for engineered buoyancy blocks, float modules, prototype subsea structures, and application-specific buoyancy components where pressure resistance, dimensional stability, and deep-water buoyancy performance are important.
Raw blanks may be sawn, cut, bonded, CNC machined, shaped, or post-processed depending on the project. They may also be used for rapid prototyping or used directly without surface treatment where the raw material finish is acceptable. The listed water absorption value refers to the raw material itself, and direct use of the blank without coating does not affect the inherent buoyancy performance of the material.
For custom projects, customers may provide CAD models, STEP files, technical drawings, final dimensions, quantity requirements, depth-rating requirements, and application notes for review. Custom blank sizes, bonded assemblies, CNC-machined profiles, and finished buoyancy components are available by quotation.
For custom blank sizes, machining, bonded assemblies, or surface finishing requests, please contact Blu-Sub at contact@blu-sub.com.
Industrial Deep-Sea Buoyancy
Blu-Float Solid Buoyancy Foam is an industrial syntactic buoyancy material designed for professional subsea use. Its epoxy resin matrix and hollow glass microsphere structure provide low water absorption, high compressive strength, and stable buoyancy performance under deep-water pressure.
Unlike ordinary foam materials, Blu-Float is intended for demanding underwater systems where dimensional stability, pressure resistance, and long-term subsea reliability are critical.
Custom CNC Machining
Quoted separately
Blu-Sub can support custom CNC machining for project-specific buoyancy blocks, float modules, trim structures, and engineered subsea buoyancy components.
Customers may provide CAD models, STEP files, PDF drawings, final dimensions, quantity requirements, and application notes for review. Custom machining is quoted separately based on size, geometry, complexity, tolerances, setup requirements, and production quantity.
Surface Finishing Options
Quoted separately
Optional surface finishing is available for machined buoyancy components where additional protection, appearance, or project-specific finishing is required.
Available finishing options may include epoxy-based filling, epoxy primer or sealer primer, baking paint, and polyurea elastomer coating. Surface treatment is normally performed after the foam has been machined to its final shape.
Professional Subsea Applications
Blu-Float Solid Buoyancy Foam is intended for ROVs, AUVs, subsea robotics, oceanographic instruments, offshore systems, underwater sensor platforms, and marine research equipment.
Its depth-rated material options make it suitable for both mid-depth and deep-sea applications where reliable buoyancy, pressure resistance, and engineered integration are required.
Factory-Direct Global Fulfillment
Shipping quoted separately
Blu-Float Solid Buoyancy Foam ships directly from our China production facility to your location. Due to the size, weight, and packaging requirements of industrial buoyancy materials, shipping is quoted separately from China.
Standard blanks are typically packaged in custom-fabricated plywood shipping crates for transit protection. Packaging may vary depending on destination-country import requirements, including rules for wooden packaging materials.
SHIPPING LIST
Technical Specifications
| Item | Density | Depth Rating | Weight | Water Absorption | Compressive Strength | Size |
|---|---|---|---|---|---|---|
| 500m Depth Rated Blank | 0.36 ± 0.02 g/cm³ | 500m / 1,640ft | ≈8,950g | ≤1% | ≥12 MPa | 500 × 500 × 100 mm |
| 1,200m Depth Rated Blank | 0.40 ± 0.02 g/cm³ | 1,200m / 3,937ft | ≈9,950g | ≤1% | ≥18 MPa | 500 × 500 × 100 mm |
| 1,500m Depth Rated Blank | 0.42 ± 0.02 g/cm³ | 1,500m / 4,921ft | ≈10,400g | ≤1% | ≥19 MPa | 500 × 500 × 100 mm |
| 2,000m Depth Rated Blank | 0.45 ± 0.02 g/cm³ | 2,000m / 6,562ft | ≈11,650g | ≤1% | ≥28 MPa | 500 × 500 × 100 mm |
| 3,000m Depth Rated Blank | 0.48 ± 0.02 g/cm³ | 3,000m / 9,843ft | ≈12,400g | ≤1% | ≥35 MPa | 500 × 500 × 100 mm |
| 6,000m Depth Rated Blank | 0.57 ± 0.02 g/cm³ | 6,000m / 19,685ft | ≈14,550g | ≤1% | ≥70 MPa | 500 × 500 × 100 mm |
NOTE: Weight is subject to actual measured weight due to edge imperfections, demolding variation, and material loss. Standard blank size is nominal only. Due to production process limitations, corner chipping, edge defects, and slight dimensional deviations are normal for raw buoyancy foam blanks. Sufficient machining allowance should be reserved when calculating finished part dimensions.
Production & Material Characteristics
Due to the production characteristics of syntactic buoyancy foam manufacturing, minor corner chipping, edge imperfections, and slight dimensional variation are unavoidable during demolding and handling of raw blanks. These characteristics are normal and do not negatively affect the inherent buoyancy or subsea pressure performance of the material.
Although density uniformity is carefully controlled during production, slight density variation may still occur and may appear visually as a gradual colour transition from darker central areas to lighter outer areas. Surface colour may also vary slightly between density grades and production batches.
Temperature Resistance
Blu-Float Solid Buoyancy Foam is suitable for conventional marine ambient temperatures. The maximum recommended material temperature should not exceed 100°C. For coated or surface-finished parts, the temperature resistance and adhesion performance of the coating system should also be considered.
Installation & Mechanical Design Guidance
This material is primarily intended to withstand hydrostatic pressure while providing buoyancy. It should not be treated as a primary structural load-bearing component for unsupported shear loads, severe impact loads, or concentrated mechanical loading unless properly engineered.
Large-diameter flat washers are recommended to help distribute fastening loads and reduce localized crushing on the material surface. Threads may be machined directly into the material where appropriate; however, fine threads are generally not recommended because small thread features may be more prone to damage.
CNC Machining Characteristics
The material contains high-density hollow glass microspheres and behaves similarly to an abrasive composite material during machining. CNC tooling intended for aluminum machining can generally be used successfully.
Recommended Starting Machining Parameters
- Spindle Speed: Approximately 3,000 RPM (depending on tool diameter)
- Feed Rate: Approximately 2 m/min
- Machining Style: Low cutting force recommended to reduce edge chipping risk
Dry machining requires proper dust extraction or vacuum collection equipment because machining generates dust containing resin particles and glass microspheres which may irritate the respiratory system. Wet machining may also be possible, but coolant compatibility testing is recommended before use. In many cases, coolant is not required.
Fixtures with large support contact areas are recommended during machining to avoid localized pressure damage. Vacuum suction fixtures and similar clamping methods may also be suitable.
Surface Finishing & Post-Processing
After machining, exposed surfaces may contain small pores caused by broken microspheres. These generally have negligible impact on overall buoyancy performance and may be left untreated if desired.
For smoother cosmetic finishes, epoxy-based putty can be used to fill surface micropores prior to coating or painting. Ordinary polyester putties are generally not recommended because their thermal expansion characteristics differ from epoxy-based materials and may increase the risk of peeling or separation over time.
Typical finishing workflow may include:
- Surface cleaning to remove dust using compressed air or vacuum cleaning equipment
- Even application of epoxy-based putty to fill exposed surface micropores
- Sanding the cured surface smooth using approximately 240–400 grit sandpaper
- Epoxy primer or epoxy sealer primer
- Baking paint finishes
- Polyurea elastomer protective coating
For thermal curing or baked finishes, room-temperature curing or low-temperature baking is recommended. Baking temperatures should generally not exceed 60°C.
Polyurea vs. Baking Paint Surface Finishes
| Performance | Polyurea Elastomer Coating | Baking Paint Finish |
| Impact Resistance | High impact resistance with strong protection against external forces | Thin coating layer with lower impact resistance |
| Appearance | Performance-oriented finish with possible orange peel texture or uneven thickness | Smoother, flatter, and more appearance-oriented finish |
| Water Resistance | Excellent | Good |
| Weathering Resistance | Strong aging and weather resistance | Moderate |
| Dimensional Impact | Requires coating allowance; typical clearance allowance approximately 2 mm | Minimal dimensional impact; typical tolerance approximately ±0.3 mm |
| Weight Increase | Non-negligible | Negligible |
| Surface Preparation | Lower surface preparation requirements | Higher surface preparation requirements |
| Coverage in Recessed Areas | May not fully reach deep recesses or internal cavities | Partial coverage of recessed areas may be achievable |
What is the difference between Blu-Float Solid Buoyancy Foam and ordinary foamed PVC or other buoyancy materials?
Blu-Float Solid Buoyancy Foam is an industrial syntactic buoyancy material designed for real subsea and marine environments. Compared with ordinary buoyancy foams, it provides higher compressive strength, lower water absorption, and better resistance to deep-water creep deformation under hydrostatic pressure.
Can raw blanks be used without coating?
Yes. The listed water absorption specification refers to the raw material itself, and direct use of unfinished blanks does not negatively affect the inherent buoyancy performance of the material. Surface coatings are typically used for additional protection, appearance, or application-specific requirements.
Is edge chipping normal during machining?
Yes. Minor edge chipping can occur during CNC machining or cutting because the material behaves similarly to abrasive composite materials containing hollow glass microspheres. Proper tooling, machining parameters, and trial cutting with leftover material can help reduce this risk.
Can chipped or damaged areas be repaired?
Yes. Minor edge damage or localized breakage can typically be repaired using epoxy resin. For larger repairs, machining dust or debris may be mixed with epoxy adhesive for filling and rebuilding damaged areas.
Can the foam be exposed to sunlight?
Long-term UV exposure may cause yellowing or surface chalking of the epoxy resin matrix. Although this does not normally affect core buoyancy performance, surface coating protection is recommended for prolonged outdoor exposure.
Are there storage requirements?
Store the material in a cool, dry location away from open flame or extreme heat sources. Although the material has better flame resistance than many ordinary buoyancy foams, it may still carbonize under extreme high-temperature conditions.
Can Blu-Sub provide custom machining or engineered buoyancy assemblies?
Yes. Custom CNC machining, bonded assemblies, engineered buoyancy structures, and surface finishing services are available by quotation. Customers may provide CAD models, STEP files, technical drawings, dimensions, quantities, and application notes for review. Please contact Blu-Sub at contact@blu-sub.com.
How is this product shipped?
Blu-Float Solid Buoyancy Foam ships directly from our China production facility. Shipping is quoted separately from China. Standard blanks are typically packaged in custom-fabricated plywood shipping crates for transit protection, although packaging configuration may vary depending on destination-country import requirements.
Do all countries allow plywood shipping crates?
Some countries have specific rules for wooden packaging materials. If plywood crating is not suitable for the destination country, alternative carton packaging may be possible, although additional cushioning may increase overall shipment volume and freight cost.
