Honeycomb panels revolutionized aircraft manufacturing as early as 1915 by allowing lighter-weight construction without reducing overall strength and durability. In fact, the hexagonal cell structure of modern honeycomb panels creates a greater strength-to-weight ratio by developing internal supports throughout the panel. This cell structure drastically reduces the panel’s material requirements and weight, reducing overall costs.
When combined with state-of-the-art facing material, such as FRP skins, honeycomb composite panels are the perfect solution for nearly any application. Over the past decade costs to manufacture these state-of-the-art cores have declined due to improved processes and increased demand, making them an affordable solution with high-quality results.
Types of Honeycomb Panels
Several materials can be used to create durable honeycomb cores used extensively across industries. From naturally derived wood and paper cores to advanced polypropylene honeycomb, these materials boast unique features and characteristics.
Polypropylene Honeycomb
Polypropylene honeycomb cores, constructed from high-quality lightweight thermoplastic, boast high strength-to-weight ratios with superior flexibility resulting in better resistance to vibrations, heat, and impact damage. Polypropylene is also naturally resistant to fungi, rot, mold, moisture, chemicals, and corrosion, making it a perfect material for high-moisture environments and applications where weight reduction and durability are critical.
Industry Applications
Composite panels with polypropylene honeycomb cores are used widely across a diverse range of industries and applications due to their lightweight and durable construction that is resistant to damage from prolonged exposure to harsh environmental conditions. Their resistance to vibrations and sound-dampening qualities make them ideal for transportation applications while aquatic applications benefit from their resistance to mold and moisture.
Aluminum Honeycomb
Aluminum honeycomb offers a unique combination of excellent strength, durability, and corrosion resistance while being able to reach and hold tight tolerances. The honeycomb structure, coupled with aluminum’s already high strength-to-weight ratio, produces superior performance where weight reduction is vital. These advanced cores are resistant to high temperatures making them the go-to solution for applications where fire rating is required or in applications exposed to temperature cycling.
Industry Applications
Composite panels with aluminum honeycomb cores are extensively used across industries for applications requiring lightweight and durable solutions. Their tight tolerance capabilities are ideal for high-tech applications requiring streamlined panels while the aerospace industry uses them to ensure long-term durability in extreme environments.
Composite Panels Built with Honeycomb Cores
The honeycomb panel is only the innermost layer of composite panels, providing internal stability and durability without drastically increasing the overall weight. Honeycomb cores are sandwiched between facing material and attached via adhesives and pressing or laminating the panel. As with the materials that make up the honeycomb, the different facing materials boast a range of benefits and characteristics.
Most commonly, honeycomb panels are faced with fiber reinforced plastic (FRP). As we discussed in greater detail in Introduction to FRP Panels: Composition, Benefits, and Common Uses, FRP panels also have a high strength to weight ratio making them the perfect facing material for lightweight requirements.
To learn more about the benefits of honeycomb cores in composite panels, please reach out to the experts at CPT today.