Composite sandwich panels are becoming increasingly popular with manufacturers and developers looking for lighter alternatives to heavier core materials such as timber to reduce the weight of their products.

To meet this growing demand, we have introduced a variety of lightweight sandwich panels to our composites range.

This new range includes a composite sandwich panel with a ThermHex core, which is a revolutionary polypropylene honeycomb that is strong and lightweight. The material’s optimised cell size and the specific structure of the honeycomb core offers exceptional surface quality and provides optimal performance in composite sandwich structures, even with very thin skin material layers.

The panels can be specified with a variety of facings, including: powder coated aluminium (0.5mm – 4.0mm), anodised aluminium (0.5mm – 3.0mm), GRP (glass reinforced plastic) including anti-slip options, painted or coated steel, high pressure laminate such as Formica or Trespa and MDF.

Alongside ThermHex, our lightweight sandwich panels are also available with a Styrofoam XPS, Aluminium Honeycomb or Banova Plywood core. All of which are suitable for use on a variety of applications including caravan conversions and linings, flooring, bodies and furniture.

Styrofoam XPS is a closed-cell high performance lightweight product that resists absorption of liquids and adhesives, which helps maintain panel integrity and has excellent insulating properties in low temperature and high humidity and moisture conditions.

Aluminium honeycomb panels are also available for more specialist applications such as marine, railway, façade and industrial applications. The panels are normally specified where flatness, strength and improved fire resistance are key factors.

Typical applications for our lightweight panels include:

  • Van conversions and lining
  • Automotive / truck bodies
  • Flooring panels
  • Structural decks
  • Furniture
  • Retail displays
  • Industrial equipment
  • Caravan and motorhome
  • Architectural
  • Bespoke
  • Public transport vehicles
  • Facades
  • Roofs
  • Partitions
  • Construction

Our lightweight panels are available to purchase online in a set of five standard specifications. Alternatively, we also offer a variety of facing material options to suit your project. These include:

  • Powder coated aluminium 0.5mm – 4.0mm
  • Anodised Aluminium 0.5mm – 3.0mm
  • GRP (Glass reinforced plastic) including anti-slip options
  • Coated Steel
  • High pressure laminate e.g. Formica/Trespa
  • MDF
  • Birch / WBP / Marine Plywood / Anti-slip Plywood

Our two factories, spanning more than 60,000 ft2, are extensively equipped with the latest technology and state-of-the-art manufacturing equipment, which includes 3 & 5 Axis CNC Board Machines, 5m x 5m Vacuum Presses, 4000mm Guillotine, Press Brake, CNC Metal Punching and Aluminium Welding.

This and our team of customer service staff, CAD designers, production operatives, and logistics specialists, means we have the capabilities to manufacture high quality, custom-made sandwich panels in both small and large quantities.

For more information or to speak to a member of our team, contact us on 0114 249 5635 or email Alternatively, to see our range of standard options and to place your order for delivery, visit our online shop.