For many years, timber panel cores have been widely used in applications such as construction, truck bodies and caravans. However, in recent years, manufacturers have started seeking lighter, more durable and sustainable alternatives.
This is especially important in vehicle manufacturing, where using lighter materials can significantly reduce fuel consumption and lower a vehicle’s carbon footprint over its lifespan. Things all changed when ThermHex was introduced.
What is ThermHex?
ThermHex is a polypropylene honeycomb core material specifically designed for use in sandwich panels and lightweight components. Its advanced honeycomb structure reduces the weight of a panel by up to 85% compared to traditional materials such as plywood, making it an ideal choice for weight-sensitive applications. ThermHex is known for its structural integrity, precision and versatility across multiple industries. This material can be ordered in standard and bespoke sizes exclusively from Panel Systems.
What are the benefits of using a honeycomb core over timber?
Manufactured using a patented process, ThermHex delivers exceptional mechanical strength and stability. Its advanced honeycomb design provides impressive load-bearing capacity and rigidity, allowing it to withstand stress and maintain structural integrity in demanding conditions.
ThermHex sheets are 100% recyclable, offering a sustainable alternative to timber panels. Unlike timber, which is susceptible to expansion, contraction and moisture absorption under significant temperature and humidity changes, ThermHex retains its shape and performance in varying conditions. It resists rot, warping and rapid degradation, even in humid or harsh environments, making it a highly reliable and long-lasting option.
The use of a polypropylene barrier film in ThermHex prevents adhesive from penetrating the open cells during manufacturing, ensuring a durable and robust bond whilst minimising material waste and enhancing overall efficiency.
Applications of ThermHex
Due to its unique combination of lightweight, strength and durability, ThermHex honeycomb cores are widely used across various industries. Typical applications include:
- Automotive: Lightweight panels help improve fuel efficiency and reduce emissions, making ThermHex a valuable material in the production of vehicle components.
- Truck Bodies: The lightweight and strong nature of ThermHex makes it ideal for truck body panels, including walls and floors, offering better load efficiency and improved fuel economy.
- Boatbuilding: Honeycomb core panels can reduce weight in boats. Moisture-resistant and corrosion-proof, ThermHex is perfect for marine environments and often used indoors, in furniture, cockpits, decks and bulkheads.
- OEM and industrial equipment: The material’s durability and load-bearing properties are well-suited for heavy-duty industrial applications such as machine covers, tool storage and conveyor systems.
- Leisure Vehicles: Reducing weight without sacrificing strength, ThermHex is an excellent choice to reduce weight in the walls, floors and ceilings of caravans, & motorhomes.
- Wind energy: ThermHex can be used in wind turbine blades due to its ability to provide strength and rigidity while minimising overall weight.
CNC machining for honeycomb panels
At our Sheffield-based factory, we specialise in creating custom sandwich panels using ThermHex, which we tailor to meet the unique requirements of your projects. Our state-of-the-art manufacturing capabilities include advanced 3-axis and 5-axis CNC cutting equipment, enabling us to deliver bespoke solutions with exceptional precision and consistency.
We offer a wide range of panel options, including standard dimensions and fully customised sizes to fit your application needs. Whether you’re working in the automotive, marine or caravan industry, our CNC technology ensures every panel is manufactured to the highest standards of quality and accuracy.
By combining expertise with cutting-edge technology, we provide bespoke solutions that help bring your projects to life, no matter how complex or demanding they may be.
To learn more about ThermHex honeycomb panels or to discuss your project requirements, contact us at 0114 249 5626 or email sales@panelsystems.co.uk.
