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A Guide to Lightweight Panel Cores

Panel Systems supplies a number of lightweight panel cores which all have a number of benefits and can be used across a range of projects for a number of purposes. Whether it’s a construction project, structural panels, refrigerated vehicles or bespoke applications, Panel Systems has the materials and the capabilities to provide materials to the exact specifications.

This guide will explain the uses for the materials we supply and the benefits of the materials for each of these applications.


In this guide:

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Lightweight panel cores: the materials and their benefits

Advances in technology mean that panels can be manufactured to be both stronger and lighter than before. For applications such as manufacturing, commercial vehicles and leisure vehicles where fuel and maintenance savings must be made, this has never been more important.

The key benefits of lightweight panel cores include:

  • Weight savings
  • Cost savings
  • Environmental savings
  • Increased strength
  • Stiffness and stability
  • Thermal efficiency
  • Water resistance

Lightweight panel cores are commonly used for:

  • Train panels
  • Buses and coaches
  • Caravans and motorhomes
  • Marine vessels
  • Furniture
  • Door panels

To find out more about the benefits and applications of lightweight panel cores, read our guide.


ThermHex is a polypropylene core material commonly used in the construction of lightweight sandwich panels.

The material forms a honeycomb structure which offers a huge amount of strength and rigidity to panel cores. ThermHex offers an extremely lightweight solution which can help to reduce costs in applications such as transportation.

The key benefits of ThermHex honeycomb panel cores include:

  • Durability
  • Lightweight
  • Strength and stability

ThermHex is commonly used across a wide range of industries and applications due to its lightweight properties as well as its strength. The sectors that benefit the most from ThermHex are:

  • Vehicle panels
  • Automotive parts
  • Transportation
  • Linings within leisure vehicles
  • Industrial manufacturing

To find out more about ThermHex and its benefits, read our guide.

Aluminium honeycomb panels

Aluminium honeycomb panels can be used across a wide range of industrial applications including architecture and transportation. The panels have a number of benefits across these applications including:

  • Lightweight
  • Rigidity
  • Thermal efficiency
  • Corrosion resistant
  • Non-combustibility
  • High dimensional tolerance
  • Sound insulation
  • Impact resistant

At Panel Systems, we have the capabilities to advise on your project from beginning to end, completing the full process in-house with our expert team. We have provided aluminium honeycomb panels for the following applications:

  • Marine
  • Aviation
  • Industrial
  • Trucks, buses and trains
  • Clean rooms

Our team are experts in our materials and panels with a full understanding of how and when they can be used so if you’re not sure the panels can be used for your application, please get in touch.

To find out more about Aluminium honeycomb panel cores and their benefits, read our guide.

Benefits of Ravatherm XPS for insulated panels

Alongside other applications, which you can find out more about in our guide, Ravatherm XPS is the perfect core material for use in sandwich panels.

The use of Ravatherm XPS as a panel core provides a stable and durable panel core with excellent thermal performance, making it ideal for use in refrigerated vehicles.

The key benefits of Ravatherm XPS when used for cold storage applications include:

  • Weight savings
  • Cost savings
  • Environmental savings
  • Thermal efficiency
  • Water resistance

Read more about the benefits of lightweight panels for cold storage in our guide.

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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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