Innovative Polypropylene Honeycomb Core

ThermHex is a polypropylene honeycomb material which is used as a core material for sandwich panels and lightweight components.

Watch our video on ThermHex and its uses


The core material is used to manufacture lightweight but incredibly strong panels, making it ideal for a wide range of applications including automotive, truck bodies, shipbuilding, OEM, industrial equipment and caravan manufacturing

Can be ordered in standard and bespoke sizes exclusively from Panel Systems Ltd.

Manufactured to order in Sheffield, from stocked materials


ThermHex is an innovative polypropylene honeycomb core material primarily used in the production of lightweight sandwich panels and fibreglass components. At our two manufacturing plants in Sheffield, we have the latest 3 & 5 axis CNC equipment and offer customers the ability to manufacture bespoke sandwich panels with ThermHex as the core.

ThermHex can be ordered in standard and bespoke sizes exclusively from Panel Systems Ltd. ThermHex sheets are available in thicknesses from 3.5mm to 28mm with cell sizes from 3 mm to 9.6 mm. Standard thicknesses are: 3.5, 6, 8, 10, 12, 15, 18, 20, 25 and 28 mm. ThermHex is available in the standard sheet size of 2500mm x 1200mm or can be cut to size, if required. Bespoke sheet sizes up to 7500mm long are available subject to minimum production quantities.

We can also bond the material to a range of facing materials, such as metals, plastics, timber and decorative laminate to offer benefits in terms of aesthetics, strength and lightness. This includes bonding with both polyurethane based adhesives. We have an extensive range of vacuum and platten presses for the manufacture of composite panels. Our fabrication capability includes three CNC routers, metal shearing and folding, aluminium welding and hot-wire foam cutting.