The benefits and uses of lightweight composite panels | A full buyer’s guide

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• The properties, benefits, and uses of lightweight composite panels – Learn more about the properties and benefits of lightweight composite panels as well as how they are used.
• How are lightweight composite panels made and how do they work? – Read more about lightweight composite panel cores and the applications of lightweight panels.
• What are aluminium honeycomb panels and how are they manufactured? – Learn more about the manufacturing process for honeycomb panels and the properties this provides.
• What are the mechanical properties of Larcore aluminium honeycomb panels? – Find out more about the mechanical properties of Larcore aluminium honeycomb panels and the applications they’re suitable for.
• Why choose Panel Systems? – Read the benefits of choosing Panel Systems.
• Frequently asked questions – We answer common queries on 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:

• Their lightweight nature makes them ideal for weight savings. For example – this means logistics companies can carry more product, deliver more parcels, and reduce fuel costs.
• Exceptional strength and durability.
• 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.
• Stiffness & Stability — Modern techniques used to create newer materials produce internal structures that are both incredibly strong and lightweight, reducing the material’s susceptibility to both bending and vibration.
• 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.

Read more about the key benefits of lightweight panels here.

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

• Marine – The strength and excellent compression properties of lightweight panels with a honeycomb core make them the perfect match for marine construction and design.
• Aviation – Lightweight panels’ lower weight and excellent functionality are ideal for aircraft, providing a way to include high-quality panelling and interior fittings
• Trucks, trains, and buses – For any vehicle where reduced weight is a benefit and long-lasting strength is a must, these functional panels can be used for ceilings, doors, luggage shelves, floors and furniture.
• Refrigerated vehicles – Used to create insulated truck bodies and bulkheads
• Clean rooms – Lightweight aluminium honeycomb panels can be paired with a wide array of, suitable facings for use in clean rooms.
• Manufacturing – The handling of light furniture is an effective option for manufacturers, allowing for easy movement and installation without sacrificing quality and strength.

At Panel Systems, we have 50 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.

Lightweight composite sandwich panels are manufactured with a core made from materials such as polypropylene / aluminium honeycomb or XPS (Extruded Polystyrene) and faced each side with an outer and inner sheet material. These panels are commonly used for both indoor and outdoor applications for purposes such as Automotive partitioning, vehicle conversions, insulation, worktops, furniture, stage platforms and various industrial applications.

They are lightweight, strong, and durable and can be produced in different ways to give them specific properties and make them better suited to specific uses. In recent years, they have become increasingly popular with manufacturers and contractors because they can help to reduce the weight of the finished products.

Lightweight sandwich panels are manufactured using an industrial adhesive to bond two thin facings (skins) onto a low-density core material. This core material provides the crucial separation between the facings. The facings are structurally adhered to the core and, when one skin is loaded with a bending force, that skin is in compression and the other in tension. The core provides the reinforcement that stabilises the skins, preventing them from buckling, so the panel has the strength to support a significant load whilst remaining lightweight and practical.

These panels provide a versatile, cost-effective solution for a wide range of applications. This is why they’re becoming a popular solution for so many industries.

Find out more about the key applications of lightweight furniture panels.

Larcore 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 resistance
• Sound insulating.

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.

Read our guide to how honeycomb panels are manufactured here.

Larcore aluminium honeycomb panels are composite panels commonly used in the transport and industry sector in order to provide a lightweight, fire safe 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.
• 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.
• Non-Combustible – Larcore panels achieve classification A2 when tested against reaction to fire standard EN 13501-1.
• 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.

Read our guide to the mechanical properties of Larcore aluminium honeycomb panels.

Contact Panel Systems today to find out more.

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 our insulated composite panels and our capabilities, please contact our team today.

How do aluminium honeycomb panels compare to traditional materials?

The key properties that set aluminium honeycomb panels aside from other popular materials include:

• Weight: Aluminium honeycomb panels are lightweight, which can reduce the cost of transport and fuel costs.
• Strength and stability: Aluminium honeycomb offers exceptional strength and durability. This allows architects and designers to utilise these panels in ways that heavyweight and fragile materials cannot be.

What factors should be considered when choosing aluminium honeycomb panels?

• Application requirements: Consider the specific needs of your project.
• Panel thickness: Choose the appropriate thickness based on structural and weight requirements.
• Surface finish: Decide on the finish based on aesthetics and durability.

Remember to consult with professionals in the specific industry for detailed project requirements and recommendations. You can contact us for guidance today.

Can you use lightweight composite panels for furniture?

Yes, Lightweight furniture panels are panels which can be used to construct furniture that is strong and sturdy but not too heavy. Lightweight furniture panels can be used to replace traditional, weightier materials such as MDF & Plywood in a wide range of scenarios, such as for kitchen worktops or cabinets, and office furniture.

• Uses and benefits of aluminium honeycomb panels
• A guide to lightweight panel cores
• What are composite panels and how do they work?
• What are lightweight furniture panels?
• The benefits of lightweight panels