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A complete guide to lightweight panels from Panel Systems

Lightweight panels are available in a range of different cores and outer facings which means they can be used across a wide range of applications and industries. Understanding the options available, their properties and the benefits when it comes to specifying lightweight panels for a project will ensure that the correct product is specified.


In this guide:

The properties, benefits and uses of lightweight composite panels

Lightweight composite panels, or sandwich panels are used in construction and manufacturing due to the many benefits they can offer.

Lightweight panels are usually made with cores such as XPS (Extruded Polystyrene), or honeycomb boards and offer an effective alternative to heavier materials such as Plywood and MDF. This is particularly beneficial within the transport industry and furniture manufacturing sector where lightweight panels are needed to create strong and durable structures.

The main properties of lightweight panels include:

  • Lightweight
  • Strength
  • Durable

These properties provide lightweight panels with the following benefits:

  • Versatile and flexible – lightweight panels can be manufactured using a variety of core materials and outer materials which means they can be manufactured to meet the specific needs of a project.
  • Thermal efficiency – when creating using a foam-based core material, these panels are perfect for applications that require heat or cold retention such as refrigerated vehicles.
  • Design flexibility – the flexibility of the panels means that they can be used across a wide range of applications.

Lightweight panels have so many benefits and are used widely in the following industries as a result:

  • Marine
  • Aviation
  • Trucks, trains and buses
  • Refrigerated vehicles
  • Leisure vehicle linings
  • Clean rooms
  • Manufacturing

At Panel Systems, we have over 45 years of experience , with an in-house CAD design service and longevity of service, we are the top choice for a wide range of project specifiers.

To find out more about lightweight panels and whether they’re suitable for your project, please read our guide.

What are the mechanical properties of Larcore Aluminium Honeycomb panels?

Larcore aluminium honeycomb panels are composite panels commonly used in the transport and industry sector in order to provide a lightweight sandwich panel solution.

Mechanical properties include:

  • Support compressive loads and tension – the structure of the panels make them able to support compressive loads and tension which is particularly important when it comes to their role within construction.
  • Stiffness and strength – this allows the panels to carry more weight and offer a longer life than other composite panels.
  • Low weight – Larcore panels are able to keep their extreme strength, despite being low weight too due to their honeycomb structure.
  • Rigidity – due to the honeycomb structure within the panels, an impressive rigidity can be achieved, making the product a market leader.
  • Flatness – achieved through the continuous manufacturing process and the materials used, Larcore aluminium honeycomb panels are valued for their flatness in a variety of industries.
  • Recyclable – Larcore panels are made from aluminium which makes them 100% recyclable, making them an eco-friendly choice.

Each of these properties makes the panels suitable for the following applications:

  • Marine applications
  • Aircraft
  • Bespoke furniture and worktop manufacturers

At Panel Systems, we are able to supply and cut Larcore aluminium panels in-house and can handle both large and bespoke orders to meet a variety of different projects.

To find out more about the mechanical properties of Larcore aluminium honeycomb panels, please read our guide.

How aluminium honeycomb panels are manufactured

Aluminium honeycomb panels are a type of composite sandwich panel which feature a honeycomb core and two outer skins providing a high strength-to-weight ratio and rigidity.

Aluminium honeycomb panels offer the following benefits:

  • Strength
  • Low weight
  • Exceptional thermal efficiency
  • Moisture and corrosion resistance
  • Sound insulating

All of these benefits make the aluminium panels extremely valuable and suitable for a number of projects. But, how are they made?

  • Step 1: Aluminium sheet passes through a printer to print alternative and parallel adhesive lines
  • Step 2: The foil is cut to the desired size and stacked
  • Step 3: A heat press is used to allow for solidification of the adhesive and to create the honeycomb block
  • Step 4: The block is then cut into the required dimensions and thickness
  • Step 5: The block is expanded to create the honeycomb structure. This is the final step in the manufacturing process
  • Step 6: The panels are fitted with a face sheet on either side.

Once they have been formed, the panels can be used within a wide range of industries including:

  • Aviation
  • Lifts
  • Marine industry
  • Buses, trains and lorries
  • Furniture
  • Doors
  • Clean rooms

The benefits of choosing Panel Systems as a supplier

At Panel Systems, we have a team of experts who can provide advice and guidance on the project from start to finish when supplying aluminium honeycomb panels.

The benefits of choosing Panel Systems include:

  • In-house CAD design – we utilise our own in-house CAD service to cut, drill, shape and design panels to meet your needs
  • Capability to manage large projects – we’re able to manage both small and large orders so please get in touch to see if we can meet the needs of your project
  • Skilled team of experts – we have a full team of experts at our headquarters in Sheffield which means we can help with the design, production and logistics of delivering your lightweight aluminium panels

To find out more about how aluminium panels are manufactured, please read our guide.

Contact us

Get in touch to find out more about pricing, or to discuss your requirements in more detail.

Get in touch to find out more about pricing, or to discuss your requirements in more detail.

Call us on 0114 249 5626

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