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Core Materials

Stone Honeycomb Panel

Most of the core in use at HONYLITE is made from honeycomb. We specify aluminum for the majority of our projects, and we process Nomex, plastic honeycomb and other core materials when required. We have expertise in customized Aluminium Honeycomb Cores.

Choosing the correct honeycomb core for your application can be a very difficult problem. Not only are there mechanical property strengths and moduli requirements, but the environmental issue must also be considered: temperature exposure, moisture, water migration, relative humidity, fluids soak resistance, damage tolerance, impact resistance, etc.

In general, aluminum honeycomb cores offer the best mechanical properties for the lowest weight and cost, while Nomex and thermoplastic honeycomb cores offer the most toughness and damage tolerance.

Sandwich Panels

Stone Honeycomb Panel

HONYLITE honeycomb panels are typically constructed of two face sheets and a core, then bonded together to form a “Sandwich Panel”. These panels exhibit performance characteristics far superior to solid structures. The principle of a honeycomb panel is similar to that of an I-beam. Through proper selection of core and face sheet materials, HONYLITE can help you design a panel with extraordinary performance characteristics. Our years of experience in design and honeycomb panel manufacturing make HONYLITE a valuable resource for all of your panel fabrication needs.

At HONYLITE we are laminating experts and offer a variety of skin options to accommodate any aesthetic application. Depending on your performance requirements, your panel can be made of aluminum, steel, fibre-glass, laminates etc. Many additional customization options are available, our sales representative will be happy to help you find exactly what you are looking for.

Edging & Finishing

Stone Honeycomb Panel

HONYLITE offers many fabrication options for many panel construction designs. Edge enclosure is typically used to:

  • hide exposed honeycomb
  • provide rigidity to edges
  • support hardware
  • seal edges from outside elements
  • place support for structural members

We have many fabrication techniques to help you design many low-cost additions to any honeycomb panel. CNC machining can be applied with edge enclosure to ensure drilling and edge profiles are done at a high tolerance
Edge Edge Edge Edge
Legs in channel edge enclosure co-fab. This option is great for strength and weight sensitive panels. C-Channel placed on panel post-fab. This is one of the simplest and cost effective edge closeouts. Legs out channel can be incorporated co-fab. This option allows us to square panels to final size. Press-brake bends can be incorporated to face sheets. This application is used commonly for walls and ceilings
Edge Edge Edge Edge
Single face sheet with press-brake bend. Aluminum tube is a great option for panels that need high strength enclosure. Solid edge enclosure comes in aluminum and wood. This edge solution is common when drilling and tapping of holes near edges is needed. Edge fill provides high strength edge enclosure to panels with unusual geometry.

These are the most commonly used edge enclosure’s options for Aluminum Honeycomb panels. Custom edge enclosure can also be incorporated with other composite panel materials.

Strength & Flatness

Stone Honeycomb Panel

There are three main factors that affect the flatness of a panel: symmetry, choice of materials, and fixturing in production.

Panels made with matching materials bonded to the two sides of the core are extremely stable. Changes in ambient temperature and humidity will not affect the flatness of a balanced panel.

Face sheet materials generally don’t vary much in thickness over the area of a sheet and therefore have little effect on flatness. Cores are more likely to vary, particularly polystyrene foam, polypropylene honeycomb and paper honeycomb. Aluminum honeycomb is manufactured to close tolerances. This is the core to choose if flatness is an issue.

There are also different methods of fixturing panels in the layup process. HONYLITE will choose or devise appropriate fixturing to meet your particular requirements. We urge our customers to consider and communicate the degree to which their application is flatness-critical.

A balanced aluminum honeycomb panel will yield the best flatness. We can provide ± 0.7mm per radial meter flatness tolerances on these panels. Panel Inserts
We offer a virtually endless amount of inserts to fit any application that we can customize to suit your panel’s needs. Potted inserts can be mounted flush to the top face of the panel and can be blind, thru holes and threaded standard or metric.

Post lay-up CNC machining, places holes in specific locations to blueprint, for insert installation. We then place inserts and adhesive fill a large internal cavity around each insert. This technique allows us to provide threads for bolts and reinforced thru holes at a high tolerance.

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