Understanding the properties of composite panels is crucial when specifying materials for a particular project or application. Each core material, along with the chosen outer layer, has distinct technical characteristics, such as compressive strength, thermal and acoustic insulation and impact durability.
In this blog, we explore the benefits of composite panels for different applications and how their core influences performance.
What are composite panels?
Composite panels, often known as a sandwich panel, are made up of two outer facings and a central core, combining strength and high performance. The core is typically low-density with a facing bonded to each side, providing support for the outer materials. The core can improve the overall impact resistance and often provide insulation. Different core materials offer different advantages:
- ThermHex (polypropylene honeycomb core): Outstanding structural performance while remaining lightweight. Allows for thicker panels without adding significant weight, making it an excellent alternative to timber cores such as plywood or MDF.
- Ravatherm XPS (extruded polystyrene): Provides superior compressive strength, durability and thermal properties, making it ideal for temperature-sensitive applications.
- Aluminium honeycomb offers an unmatched strength-to-weight ratio and rigidity, making it suitable for technical heavy-duty structural panels
- Recycled PET (foam core): Lightweight and environmentally friendly, providing good insulation, impact resistance and sustainability for a variety of applications.
At Panel Systems, we provide a wide range of composite panels, offering the ability to produce bespoke sizes and specifications. Our facing materials include powder-coated aluminium, anodised aluminium, glass-reinforced plastic (GRP), coated steel, high-pressure laminate and anti-slip plywood.
What are the benefits of composite panels?
One key benefit of composite panels is their lightweight construction, yet they have an impressive strength-to-weight ratio, making them ideal for projects that demand both structural performance and mechanical reliability. Their reduced weight not only lowers material costs but also makes transportation more efficient compared to heavier solid materials.
These panels can help mitigate noise, which is particularly useful in urban areas, near busy roads or in vehicles like caravans. Using higher-density cores further enhances sound insulation, protecting against both internal and external noise.
Known for their high compressive strength, composite panels can bear heavier loads than many alternative materials, while impact resistance ensures durability in demanding applications.
By choosing different core and facing combinations, composite panels can be customised for a wide range of applications, from vehicles to buildings to refrigerated storage units.
Where are composite panels used?
Composite panels are widely used in cars, trucks, buses and other large vehicles, lining ceilings, floors, walls and doors. Compared to conventional structures, they are lighter, which reduces fuel consumption when transported. They also provide effective thermal insulation and structural support.
Refrigerated trucks benefit from insulated composite panels, which retain cold temperatures more efficiently, therefore reducing energy consumption. Caravans and campervans use composite panels for lightweight construction and noise reduction.
As composite panels contribute to creating temperature-controlled and hygienic environments, they can be used the line cold rooms, such as chillers, to create a thermal and vapour barrier.
In construction, sandwich panels are valued for their combination of decorative facings and insulated cores, which enhance thermal efficiency, energy performance and aesthetics. They are commonly used for walls, ceilings and modular structures.
Why choose Panel Systems?
At Panel Systems, we have extensive capabilities combined with over 50 years’ experience. Our team includes Technical Estimators, CNC Programmers, Production Operatives and Logistics Experts, all working together to deliver bespoke solutions tailored to your specific requirements.
With our in-house CAD designers, we can incorporate customers own drawings and convert them for use in CNC machining the finished parts. To make the process even more convenient, we offer cutting services, ensuring your panels arrive at the right location in the correct detail.
This streamlined approach means our customers avoid lengthy wait times and don’t need to co-ordinate additional third-party fabrication, making Panel Systems a complete and reliable solution from design to delivery.
To find out more about our insulated composite panels and our capabilities, please contact our team today.
