Lightweight Panels for DIY Campervans

The coronavirus pandemic has brought global travel plans for many across the world to a standstill. As such, there is set to be a subsequent rise in the number of people throughout the UK choosing to holiday in the country or taking a ‘staycation’.

Even before the pandemic, over two million Brits were choosing to take ‘staycations’ each year in rented or owned caravans or motorhomes. Now however, it is expected that even more holidaymakers will steer towards UK camping trips and caravan holidays, as they look for further ways to increase social distancing and reduce holiday costs.

As a result of this, there has been an increase in the number of people choosing to fit out their own campervans or motorhomes to reduce their costs even further. In fact, according to the DVLA (Driver and Vehicle Licensing Agency) applications for vans to be converted to living spaces has jumped by almost two-thirds.

In line with this, we have seen online sales of our range of lightweight panel cores rise, particularly Thermhex, the innovative polypropylene honeycomb core material. Thermhex is suitable for use throughout a motorhome, campervan or caravan as a lightweight alternative to timber and is often used as a core material for lining the floor and body, as well as internal components such as furniture units.

Thermhex is up to 80% lighter than a like-for-like thickness of plywood, yet is extremely strong and rigid, but can be shaped as required, all properties that make it appealing to the leisure vehicle industry.

Manufactured in Germany in an innovative, patented process which ensures rigidity in terms of its mechanical strength, as well as stability, Thermhex is resistant to chemicals and moisture. In addition, as part of ensuring ethical and sustainable sourcing of materials, it is also 100% recyclable.

Already well established as a material of choice across mainland Europe, Thermhex is also suitable for a number of other applications including boats, furniture, OEM, industrial equipment and commercial vehicles.

The material can be purchased online direct from our website for delivery anywhere in the UK, in a standard sheet of 2500mm x 1200mm, or we can supply bespoke sizes up to a maximum of 7000mm x 1200mm (minimum order quantities apply). Thermhex is supplied in thicknesses ranging from 3.5mm to 30mm and is also available in different core densities to suit specific applications.

We have also experienced increased demand for our lightweight sandwich panels which utilise a Thermhex core. These are available with a variety of facings, including: powder coated aluminium (0.5mm – 4.0mm), anodised aluminium (0.5mm – 3.0mm), GRP (glass reinforced plastic) with anti-slip options, painted or coated steel, high pressure laminate such as Formica or Trespa, plywood and MDF.

Pre-manufactured sandwich panels are suitable for use in various areas of caravan or motorhome conversions including wall linings, flooring, furniture panels and structural decks and can be purchased through our online store in a range of standard specifications and sizes

If you are unsure on what core thickness or facing would be most suitable for your motorhome or campervan, we can also offer technical assistance in selecting the right size and material for your application and performance requirements.

In addition, our 3 and 5 Axis CNC routers with a bed size of up to 3000x2000mm allow for the production of flexible designs and panel shapes. This means our skilled Sales and CAD/CAM team is also on hand to bring your ideas and designs to life, and can advise on specific cutting details, suitable materials and capabilities.

Over the past 40-plus years, we have built a reputation for offering innovative, bespoke panel solutions for a diverse range of markets ranging from leisure and playground equipment to caravans, truck bodies, the window industry and construction.

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