Builders and engineers have taken advantage of the benefits of composite materials since before recorded history. By combining two or more materials they could enhance the desired features, producing stronger, more reliable components used to construct amazing architecture still standing today. Composite panels put a modern spin on this idea by utilizing the most advanced materials, carefully constructed with cutting-edge technology.
A composite panel is typically constructed by layering a specially designed core between two outer skins, producing lightweight and durable solutions. Depending on the materials, these lightweight composite panels feature a wide range of characteristics that makes them ideal for use across diverse applications.
Types of Composite Panel Materials
From lightweight and corrosion-resistant aluminum to budget-friendly wood cores, each material produces unique results.
Cores
The core of any composite panel provides the main structural component. These cores are often constructed with a honeycomb-like cell structure. This allows for reduced material requirements while improving the overall strength and durability.
Polypropylene Honeycomb
Constructed from lightweight thermoplastic, polypropylene honeycomb cores boast high strength-to-weight ratios coupled with sturdy hexagonal cell construction, making them ideal solutions for applications where weight reduction and durability are critical requirements. Composite panels with polypropylene honeycomb cores also provide superior flexibility resulting in better resistance to vibrations, heat, and sound making them popular options for the transportation and automotive industries.
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 characteristics make aluminum honeycomb composite panels highly sought after for high-tech applications that require ultra-flat precision panels.
Insulated Foam
Foam cores, available in several chemical formulations, have outstanding thermal and insulating properties. This insulating nature makes them ideal for temperature-sensitive applications such as refrigerated trailers and all-weather recreational vehicles, Depending on the formulation, these cores boast a range of strength-to-weight ratios, allowing for a wide range of uses across applications and industries.
Paper Honeycomb
Paper honeycomb provides an economical and lightweight solution for durable composite panels. When coated to resist heat and moisture, these panels are ideal for construction, marine, and transportation applications.
Wood
Wood has been a staple in composite materials from the beginning and still has practical applications today. This budget-friendly option is perfect when weight isn’t as big of an issue and the panels won’t be exposed to harsh environments, such as the interior of marine vessels.
Skins
Making up the outer layers, the facing material also known as the skin, protects the inner core and provides additional durability and strength. While every material improves the panels’ overall performance and contributes to the visual appeal, each type of skin provides unique features.
Aluminum
Aluminum is a lightweight and malleable material, making it an ideal facing material for applications requiring bent edges and bends in the panels. It’s also highly resistant to corrosion and fire. These combine to make aluminum facing perfect for the transportation and automotive industries.
ABS, Fiberglass, Fiber Reinforced Plastic (FRP)
As highly customizable facing options, ABS, Fiberglass, and FRP are used extensively throughout automotive, transportation, marine, and construction industries. These facing materials not only provide additional strength and durability to the composite panels, but also allow for branding opportunities with custom colors, textures, and other decorative additions.
Stranded Polypropylene
Stranded polypropylene provides a cost-effective skin for composite panels where physical attractiveness isn’t particularly important, such as insulating sleeper cabs from the heat and sounds of the engine compartment. As a lightweight, durable, and insulating material, stranded polypropylene composite panels are used across all industries.
Rubber and Vinyl
When the skin does not have to provide additional structural support but needs to protect the panel against impact damage, rubber and vinyl facing materials are ideal options. These materials also provide custom color and texture variations to help enhance the appearance of the finished product.
Steel
Steel is used as a facing material in high-impact applications and harsh environmental exposures, such as those found in the agricultural and construction sectors. This is the perfect skin for panels that need to stand up to repeated abuse and the added weight won’t hinder performance.
Wood
Wood skins are an attractive and cost-effective facing material used throughout construction and other applications that are not exposed to harsh environments.
Composite Panels: Unique Benefits Across Diverse Applications
Whether you’re looking to improve the comfort and safety of your drivers with custom cab extensions, or looking for ultra-thin precision panels for your innovative high-tech gadget, composite panels provide effective solutions and a range of benefits. With 25 years of industry experience, the experts at CPT can help you design the perfect composite panel to meet your exact needs.