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.
A sandwich panel consisting of 3D Core PET (a unique, high performance, conformable polyethylene terephthalate foam core material ideally suited to resin infusion) sandwiched between two layers of polymethyl methacrylate (PMMA), acrylic.
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.
A honeycomb development from ThermHex. Made in exactly the same way as the current EconCore technology, the wavy profile improves the stability of the honeycomb wall, enhancing strength to weight and compressive strength by up to 2x at low densities.
Strips of kraft paper glued at intervals to create a honeycomb structure when expanded. This kind of material is used to make the core of lightweight doors, packaging and sandwich panels.
Structural sandwich panels with with aluminium honeycomb core. Typically, aluminium alloy 3003 or 5052 are used. Glass fibre reinforced epoxy skins provide excellent stiffness- and strength-to-weight. Aluminium faced honeycomb panels are relatively heavier, but offer excellent mechanical properties combined with a durable and decorative surface. Aluminium alloy 1050 is one of the most common sheet materials used where no special mechanical or chemical properties are required.
Composite automotive sandwich panel floor assembly for Zenos E10 sports car, with thermoplastic honeycomb core and carbon fibre reinforced polyurethane resin (PUR) skins, produced with spray-up compression moulding by Bright Lite Structures
Futures HS 4.20 Generation Series designed by Hayden Cox. A mix of materials is used to create the ultimate ride performance. Carbon fibre and glass fibre are used in combination with a nonwoven polyethylene terephthalate (PET), polyester, honeycomb shaped core material. Epoxy resin is infused into the materials under vacuum. The honeycomb has very low resin uptake and saves around one-third of the weight compared to solid laminate.
Lightweight wood faced sandwich panel consisting of nomex honeycomb core sandwiched between two layers of poplar plywood. It is used for interiors and furniture.
Decorative wood faced sandwich panel consisting of nomex honeycomb core sandwiched between two layers of lightweight beech plywood. It is used for interiors and furniture.
Spot Material is a database of materials for sustainable design, curated by Rob Thompson. Compare properties, carbon and end of life, find better alternatives and discover new material innovations. Browse all materials
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