What are the types of lightweight panel cores and what are their benefits?

Click on a link to jump to that section:

• Lightweight panel cores: the materials and their benefits - Find out more about the benefits of lightweight panel cores and the different materials.
• Benefits of Ravatherm XPS for insulated sandwich panels - Find out more about the benefits of using Ravatherm XPS from Panel Systems for insulated panels.
• Why choose Panel Systems? - Read the benefits of specifying a product from Panel Systems.
• Frequently asked questions - We answer common queries on lightweight panel cores from Panel Systems.

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 fit outs
• Buses and coaches
• Caravans and motorhomes
• Marine vessels
• Furniture
• Retail displays
• Door panels.

Read more about the benefits and applications of lightweight panel cores here.

Shop our range of lightweight panels here.

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.

Read our guide to the benefits of aluminium honeycomb panels here.

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.

Read our guide to aluminium honeycomb panels and their benefits here.

ThermHex

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 ThermHex and its benefits.

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.

The team at Panel Systems is highly experienced with lightweight sandwich panels and can assist with material selection in order to determine the right specification for your project.

Panel Systems not only offers this expertise, we also provide an in-house CAD design and CNC cutting service so we can handle your project all the way through, with advice on-hand whenever you need it.

This gives us the ability to handle bespoke projects and no project is too large or small. We work with clients of all sizes who require panel solutions for a wide range of purposes and always deliver on our client’s needs.

Panel Systems supply both the panels and a bespoke cutting and fabrication service so we can have them ready for your desired application upon delivery. From initial consultation to design to production, we provide a full-service solution to help you produce the perfect panels for your project. We also have a diverse range of facing and core material options, increasing our versatility to suit the widest possible range of clients.

If you need lightweight sandwich panels for your project and would like expert advice, please contact our team today.

What materials are commonly used as the core in lightweight sandwich panels?

Lightweight sandwich panels typically feature cores made of Extruded polystyrene (XPS) and Recycled PET Foams. Other advanced cores include aluminium honeycomb and polypropylene honeycomb. The core material is selected based on its ability to deliver high strength while keeping the overall weight low.

What are the primary advantages of using lightweight cores in sandwich panels?

The primary benefits of using lightweight cores include reduced weight, which is essential in applications like transportation and construction. The core also provides thermal insulation, excellent load distribution, and sound absorption. The panel remains rigid and structurally robust despite its light weight. Read more about the benefits of lightweight panels here.

Can lightweight cores handle high loads or impact forces?

Yes, lightweight cores, particularly honeycomb structures or higher-density foams, can handle significant loads and impacts when correctly engineered and paired with suitable facing materials. They excel at spreading loads across the entire panel surface, reducing the stress on individual points.

How are lightweight sandwich panels customised for specific applications?

Panels can be customised by selecting the appropriate core material and facing sheets to meet specific requirements. The thickness, density, and overall dimensions of the core are adjustable, and the outer skins can be made from aluminium, GRP, MDF, ABS, PVC or steel depending on the application.

What factors should I consider when choosing a lightweight core material?

When selecting a lightweight core, consider the application's load-bearing requirements, thermal insulation needs, reaction to fire, and budget constraints. For example, honeycomb cores excel in load-bearing and impact resistance.

Can lightweight panels be used in outdoor applications?

Yes, many lightweight panels are suitable for outdoor use if they have appropriate moisture resistance and weatherproof facing sheets. The core must also be water-resistant if it's exposed to outdoor conditions. Consult with the manufacturer to ensure the chosen material is suitable for external environments. Read our guide to the key applications for lightweight composite panels to find out more.

The uses and benefits of aluminium honeycomb panels

Benefits of thermhex polypropylene

How are aluminium honeycomb panels manufactured?

Key applications for lightweight composite panels