Skin and Core Materials

Kraft / Phenolic Honeycomb

18% phenolic resin impregnated Kraft paper. Available in 3/8", 1/2" and 1" cell sizes.

Aluminum Honeycomb

Thin sheets of 3000 series Aluminum alloy foil bonded together in an alternating pattern that is expanded to form a cellular honeycomb shape. Standard foil thickness is 0.003". Available in 1/8", 1/4", 3/8", 1/2" and 1" cell sizes.

Polypropylene Honeycomb

Polypropylene tubes, thermally fused together to form a honeycomb block. The block can be cut to any thickness to yield various core slices. 5 lbs per cubic foot in 8mm (.315") size is standard.

Polystyrene Ribbon Honeycomb

Thin ribbons of Polystyrene plastic welded at the nodes to form a square cell. Offers many of the advantages of Polypropylene honeycomb, but at a lower weight and cost.

Aramid Fiber (Nomex™) Honeycomb

Manufactured from DuPont's Nomex™ paper sheets. An adhesive is used to bond the sheet at the nodes; after expanding, the core is dipped in a phenolic resin and cured. Available in cell sizes from 1/8" to 3/8".

Urethane Foam Filled Honeycomb

A hybrid core material that combines the shear capabilities of Honeycomb and the compression properties of urethane foam. Available with either Kraft / Phenolic or Polyester fiber honeycomb.

Polystyrene Foam

Available in both extruded (XPS) and expanded (EPS - bead type), these products can provide a surprisingly strong, lightweight if thickness and skin material are properly chosen. Standard density is 2 lbs. per cubic foot.

Polyisocyanurate Foam

Frequently used as a substitute to Polystyrene foams when fire resistance is a concern.

Rigid PVC Foam

A high-performance closed-cell foam that provides an excellent overall combination of properties. Available in densities from 3 to 12 lbs. per cubic foot.

Urethane Foam

A rigid structural closed-cell foam available in densities from 2.5 to 20 lbs. per cubic foot.

Polyethylene Foam

A thermoplastic foam that has similar structural properties to Polyurethane foam. Standard density is 8 lbs. per cubic foot.

Plywood

Low cost and high strength, but heavy.

End Grain Balsa

Strong and lightweight, but expensive compared to most standard cores.

Fluted Polypropylene

Low cost with excellent moisture/corrosion resistance, but lower in strength than Plastic honeycomb.

 

SKIN (FACING) MATERIALS

METALS:

Aluminum

Lightweight metal, with a high strength-to-weight ratio. It is moisture and corrosion resistant and non-flammable. Available in many decorative finishes, including painted or anodized, melamine-faced, and vinyl clad.

Steel

A high strength metal with good impact resistance. Available in a variety of finishes, including painted, bonderized, and galvannealed (which makes Steel more corrosion resistant).

Stainless Steel

A high strength material with good impact resistance. It is corrosion resistant and available in decorative finishes.

COMPOSITES:

Woven Fiberglass

A strong material, offering excellent impact resistance. It is moisture and corrosion resistant.

Prepreg Fiber

Very lightweight with high strength ratings. It is moisture and corrosion resistant and available in a number of fibers & weaves. Resins are tailored to usage.

POLYMERS:

Laminates

Available in many decorative finishes (for examples, visit Wilsonart®) and in fire resistant versions.

Plastic Sheet (ABS, Polypropylene, Kydex™, etc.)

Lightweight material with good impact resistance. It is also moisture and corrosion resistant and available in a variety of colors and textures.

Extruded FRP

Stronger than Plastic sheet. Also moisture and corrosion resistant, it comes in many colors and textures.

WOODS:

Plywood

A high strength, low cost option, but heavy. Good impact resistance.

Hardboard

Very low cost material with a smooth uniform surface. Available in decorative finishes, painted, and melamine-faced varieties.

Prefinished Veneer

Lightweight, available in highly decorative finishes.

MDF

MDF is a low-cost, low-weight and medium strength engineered wood product form fibers and wax resin.

Nomex™ is a registered trademark of E. I. DuPont de Nemours Company
Kydex™ is a registered trademark of Kleerdex Company