Spheretex Introduction

Sphere Tex Logo

Laminate Bulker

Carbon-Core Corp.’s Spheretex products offer:

  • Ease of use
  • Constant thickness
  • Deformability
  • Anti-shrinkage
  • Low resin consumption
  • Permanent bulk
  • Print-through blocking
  • Excellent fatigue resistance
  • Cost and labor effectiveness

Spheretex is non-woven textile made from fine polyester fiber, manufactured in a continuous process similar to needlepunched felt. As the fiber is processed a 50% by volume load of hollow polyacrylonitrile microspheres is introduced along with an acrylic binder.

Perforations to facilitate faster resin saturation are hot needled into the Spheretex as a final process before coiling and converting.

Spheretex Carbon MatSpheretex Carbon Mat


Most laminate bulkers available in the marketplace today are made of polyester fiber and glass microspheres.

Spheretex has MULTI-DIRECTIONAL fiber orientation.

Unlike the unidirectional fiber orientation used in bulker products manufactured by most of our competitors, our multi-directional fiber orientation provides equal strength characteristics in both length and width directions. It also helps in wetting out the laminate equally in both directions, as opposed to easier wet out in one direction in linear fiber products.

Spheretex is easily recognized by its more frequent perforations, which help in the wetout of the material and create more vertical links as well as easing the evacuation of trapped air bubbles throughout the laminate.

  • Print blocking: Thinner-grade Spheretex is a very effective print-through barrier when placed behind a skin coat.
  • Screw retention: Spheretex adds excellent screw retention capability to a laminate, and can be placed, for example, around the perimeter of swim platforms for rub rail installation.
  • Microcracking prevention: Spheretex reduces demolding cracks and stress cracks in gel coated parts.
  • Spheretex performs at a level well above that of competitive products. Its shock resistance is 35 to 50 percent higher, one reason why products made with Spheretex obtain longer useful life cycles. Water absorption is equivalent to that of the competition. Its even, multi-directional fiber distribution offers reinforcement characteristics not available in competitive products.

Spheretex exhibits superior impact and shear strength, thanks to stronger links between the different layers within the mat as well as excellent resin distribution throughout the product.

Spheretex’s excellent impact values underscore the ability of the Spheretex-reinforced laminate to meet toughness requirements and withstand severe-duty fatigue.


Fabricators who use Spheretex can realize as much as a 60 percent weight savings compared to bulking laminate with fiberglass. One layer of Spheretex 301 replaces three layers of 1.5-oz chopped strand mat. Chopped strand mat 1.5 oz – Spheretex – Chopped strand mat 1.5 oz
(Impregnation: Spheretex with 600 g/m2/mm, CSM with 1000 g/m2)

Fast and easy handling


Core material is reinforcement material as well


Same resin type for core and covering layers


Homogeneous laminate with low water absorption


Core material with low specific weight, but monolithic laminate properties


Glass core materials with enormous impact and shear strength combined with low weight


High surface quality (Class A)


Spheretex Applications


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