Cross-section through the detachable roof modules of the Ford Bronco. This part is made with a thermoformed thermoplastic outer layer, which is back-moulded with glass fibre and polyurethane resin (PUR), plus a Nomex honeycomb core for increased thickness (stiffness with minimal additional weight). It is manufactured by compression moulding, whereby the thermoformed polycarbonate (PC) is placed into the mould, onto which glass fibre and honeycomb are laid. A precise dose of PUR is applied by spraying on the layers and then the whole assembly is compressed in a mould and heated to cure.

Light Light Chair, designed by Alberto Meda for Alias, 1987, is manufactured with Nomex honeycomb core sandwiched between layers of unidirectional carbon fibre reinforced epoxy. Weight is c. 1 kg. Image Alberto Meda.

Press-moulded sandwich panel from ThermHex EconCore polypropylene (PP) honeycomb sandwich panel for automotive interior application. The PP core is sandwiched between PP skins and over-moulded with PP to create features on the edge. PP is used throughout, ensuring the product remains fully recyclable as a monomaterial.

Press-moulded sandwich panel from ThermHex EconCore polypropylene (PP) honeycomb sandwich panel, for automotive interior application. The PP core is sandwiched between PP skins ensuring the product remains fully recyclable as a monomaterial.