What are lightweight furniture panels? | Exploring their uses and benefits

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• What are lightweight furniture panels? - Learn more about what lightweight furniture panels are and how they’re made.
• What materials are used to create lightweight furniture boards? - Find out more about both the facing and core materials that are used to create lightweight furniture panels and their benefits.
• Key benefits of lightweight furniture panels - Learn more about the benefits of using lightweight furniture panels.
• What are lightweight furniture panels used for? - Find out more about the key applications for lightweight furniture panels.
• Choosing Panel Systems as a supplier of lightweight furniture panels - Find out more about Panel System’s capabilities when it comes to supplying and cutting lightweight furniture panels.

Lightweight furniture panels are panels which can be used to construct furniture that is strong and sturdy, without being too heavy. These panels are manufactured as a sandwich construction by bonding outer layers of decorative material to a lightweight core material (usually extruded polystyrene foam (XPS) or honeycomb). They are similar in stability to wood and more solid, expensive materials.

Lightweight furniture panels are constructed using a wide range of different materials, both in terms of the facing materials and core materials. The facing material will depend on how the panels are being used and the look they provide. In addition, when it comes to core materials, it’s important to consider how the panels will be used to ensure the panels are suitable for the application.
Facing materials

In terms of facing materials, the following can be used for lightweight furniture panels:

• Melamine faced MDF – This offers a slightly textured surface which does not require painting to look finished and is suited to furniture of all types. From desks, retail displays, bookcases and more, this material will provide the same look as solid wood furniture, without the associated weight.
• Plain MDF – is another choice which can, again, be used for a range of furniture types and may be finished with paint where required.
• Plywood – plywood has a great look and can be used to create a range of furniture and lining components, including furniture that is used within vans or caravans. Ideal for desks, it creates the look of a much heavier wood-based panel, without the weight. Plywood is a fantastic choice for offices or schools who want a uniform look to their furniture.
• High-pressure laminates – this material can be used to create incredibly durable, decorative surfaces, which are also water-resistant. This makes it especially suitable for environments with a lot of water, steam and general dampness, such as washrooms.
• Aluminium – offering excellent strength and durability, aluminium helps to improve rigidity and protect the panels from damage. It can also be supplied in a huge number of powder coated colours

View our lightweight sandwich panels here.

Core materials

When specifying a lightweight panel, there is a range of options available, again, to meet the needs of different applications and projects:

• • Ravatherm XPS (extruded polystyrene) – Ravatherm XPS is a popular choice due to its lightweight and durable properties as well as its high compressive strength. It is also available in any thickness from 3 – 160mm in increments of 0.5mm.
  • Paper honeycomb – this material is often chosen as a core material for interior furnishings. It can also be used to create partition walls. Very lightweight, it is also a great low-cost option, meaning the panels can be thicker while still keeping costs down. Read our guide to lightweight panel cores here.

• ThermHex polypropylene honeycomb – with a lightweight finish, this material is extremely stable and strong. Its finish makes it easy to bond with other materials, so a wide choice of facing materials is available when this material is used. Find out more about ThermHex polypropylene honeycomb here.

• Aluminium honeycomb – An aluminium honeycomb core allows the panels to offer extreme strength, despite being low weight. The structure of the panels makes them able to support compressive loads and tension. Find out more about aluminium honeycomb panels.

View our lightweight aluminium honeycomb panels here.

Lightweight furniture panels have a range of great benefits over and above other types of panels available:

Lightweight

The panels provide a lightweight solution while still being sturdy and suitable for a wide range of uses in a range of different environments.

These panels offer a similar stability to solid wood, with a similar aesthetic appeal. Read our full guide to lightweight panels from Panel Systems.

Strength and durability

It is possible, with panels of this nature, to reduce the overall weight of the furniture without compromising on strength or durability. They provide a resistant surface so the panels will withstand daily use.

Reduced transportation costs

Lightweight furniture panels weigh much less than solid wood or solid material panels so cost much less to pack and transport.

Find out more about the benefits of lightweight furniture panels here.

Sustainability and the environmental impact of lightweight furniture panels

Less weight means less fuel and less CO2 emissions. This is particularly attractive to larger brands and manufacturers serving the general public — for example, the food and leisure industries. Alongside weight reduction, the core materials in lightweight furniture panels provide excellent strength to weight ratio. We offer a range of lightweight, high strength cores including polypropylene honeycomb, aluminium honeycomb and XPS foam (extruded polystyrene).  

At Panel Systems, we are committed to continually improving our environmental performance and periodically monitor and review our  performance.

Read our environmental policy here.

Flexibility and customisation benefits

Lightweight furniture panels offer unique design possibilities due to their versatility and ease of customisation. Customisation extends beyond surface finishes. The core materials, such as Ravatherm XPS, paper honeycomb, and ThermHex polypropylene honeycomb, can be specified in various thicknesses and densities to meet specific structural requirements without compromising on weight. This adaptability makes lightweight composite panels from Panel Systems suitable for a broad range of applications.

Panel Systems’ manufacturing capabilities allow for bespoke cutting and shaping, ensuring that each panel precisely fits the intended design or architectural feature.

Lightweight furniture panels can be used to replace traditional, weightier panels in a wide range of scenarios:

Caravans and leisure vehicles

Lightweight furniture panels are used in motorhomes such as caravans and leisure vehicles, with the lighter weight resulting in fuel savings.

Kitchen worktops and cabinets

Lightweight furniture panels can also be utilised in kitchen and bathroom cabinets or kitchen worktops. Within the home they are an excellent choice for tabletops and can be used for a wide range of commercial and domestic furniture.

Office & retail furniture

Outside the home, a lightweight furniture board is suitable for used in office furniture (for desks, tables and more), hotels and even to create retail shelving which is light yet sturdy and resistant to the constant use it will be subject to.

Lightweight panels are used for point of sale displays and general wall panelling that is aesthetically appealing and adaptable.

School furniture

Lightweight furniture panels are often used in school furniture such as tables, benches, and desks to provide furniture that can withstand heavy use, but which can also be easily moved and stacked.

Panel Systems excels in supplying lightweight furniture panels, backed by an expert team with access to the latest tools for bespoke and large-scale projects. With 50 years of experience, our in-house capabilities in cutting and CNC machining allow us to meet exact project specifications efficiently, avoiding communication issues or delays associated with off-site services.

Our team's deep expertise ensures projects are delivered on time, tailored to the correct standards, and supported with comprehensive guidance.

To find out more about Panel System’s capabilities and delivery information, please contact our expert team today.

What is ThermHex?

ThermHex is a strong & lightweight material that provides optimal performance in composite sandwich structures where superior mechanical performance is required. The optimised cell size and the specific structure of ThermHex honeycomb cores offer an exceptional surface quality in sandwich components even with very thin skin material layers. Find out more about ThermHex here.

What are lightweight furniture panels?

Lightweight furniture panels are constructed to offer strength and durability while being significantly lighter than traditional solid wood or MDF panels, making them ideal for applications where weight is a concern. Find out more about the benefits of lightweight panels in our guide.

What materials are used in lightweight furniture panels?

They typically consist of a lightweight core material like XPS, or honeycomb, and are faced with materials like plywood, MDF, or laminates.

Where can lightweight furniture panels be used?

They are used in caravan and campervan interiors, lightweight doors, architectural applications, for vehicle conversion furniture, and wherever weight reduction is essential.

How are lightweight furniture panels manufactured?

Panels are made using a lamination process that combines the core sheet material with the facing material, often involving pressure and adhesive to create a strong bond.

Can lightweight furniture panels be customised?

Yes, many manufacturers offer bespoke cutting and finishing services to meet specific project requirements. Read more about the benefits of choosing Panel Systems.

The benefits and properties of lightweight composite panels

What are composite panels and how do they work?

How are aluminium honeycomb panels manufactured?

Key applications for lightweight composite panels