When it comes to building lighter yet stronger products, choosing the right core material can make all the difference. Thermoplastic honeycomb cores, like ThermHex, are ideal across many industries due to their unique composition, which makes them the perfect choice for sandwich panels.
In this blog, we’ll explore what makes ThermHex so versatile, how it works as a panel core and why it is a popular solution for manufacturers looking to optimise performance, efficiency and durability.
What is Thermoplastic honeycomb core?
Thermoplastic honeycomb cores made from polypropylene, such as ThermHex, are used to produce
lightweight yet incredibly strong sandwich panels. These panels are widely used in automotive
applications, shipbuilding, industrial equipment and leisure vehicle manufacturing.
This material is produced using a patented process that forms a hexagonal honeycomb structure, which is placed between outer skins to create a sandwich panel, that provides exceptional mechanical strength and stability.
Finished with a polypropylene barrier film, it restricts resin or adhesives from soaking into the open cells and affecting mechanical performance. ThermHex can also be finished in a PET non-woven material for easy bonding to a range of facing materials, such as metals, plastic, timber, and decorative laminate.
What are sandwich panels?
A sandwich panel is a composite structure consisting of three layers. It consists of a lightweight core material which is sandwiched between the two outer layers. The core can be made from a polypropylene honeycomb, aluminium honeycomb or XPS foam (extruded polystyrene). Most of our lightweight panels use ThermHex honeycomb core, as it is lightweight, yet has an extremely rigid structure.
Why are thermoplastic honeycomb sandwich panels so strong?
For applications requiring high strength with low weight, honeycomb core sandwich panels can
replace heavier solid materials. This strength comes from even load distribution as the hexagonal cell geometry spreads loads evenly across the panel. Honeycomb cores significantly increase the panel stiffness without adding excessive weight. The air-filled cells also reduce material usage while maintaining structural integrity.
Benefits of honeycomb sandwich panels
Compared to traditional composite cores, honeycomb sandwich panels offer numerous benefits.
Lightweight: Honeycomb cores dramatically reduce weight compared with solid plastic sheets or timber panels. Thanks to its polypropylene honeycomb structure, the weight of the sandwich panel can be reduced up to 85% compared to traditional materials.
High impact resistance: The cellular structure absorbs energy and improves durability, providing impressive load-bearing capacity and rigidity, allowing the panels to withstand stress.
Corrosion and moisture resistance: Unlike timber cores, polypropylene honeycomb materials are resistant to moisture, retaining their shape and performance in varying conditions.
Recyclable: ThermHex sheets are 100% recyclable, offering a sustainable alternative to timber
panels.
Where are thermoplastic honeycomb cores used?
Thanks to their versatility, honeycomb cores can be used in a wide range of industries, including automotive manufacturing, shipbuilding, industrial equipment and caravan production.
1. Automotive
Lightweight panels can contribute to greater fuel efficiency and assist in reducing emissions, making ThermHex a valuable material in the production of vehicle components. ThermHex core with glass-reinforced plastic facings can deliver up to 41% weight savings compared to traditional 18mm plywood core panels. This significant reduction in weight makes commercial vehicles more fuel-efficient, cost-effective to operate and better for the environment.
2. Truck Bodies
In refrigerated trucks and vans, sandwich panels with honeycomb cores are the ideal solution for maintaining precise temperature control. Thanks to their lightweight yet strong structure, ThermHex provides excellent insulation while keeping overall vehicle weight low. Used in insulated walls, floors, and ceilings of refrigeration units, these panels help trucks operate more efficiently by reducing heat transfer, keeping goods at optimal temperatures throughout the journey.
3. Boatbuilding
Moisture-resistant and corrosion-proof, ThermHex is perfect for marine environments and often used in boat construction – cockpits, decks and bulkheads.
Packaging
Honeycomb sandwich panels are commonly used in reusable transport packaging and pallets because of their ability to provide great strength without excessive weight.
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. They also allow for easy
customisation, enabling shelving, tool racks and workbenches to be mounted while maintaining a
clean and professional finish.
Leisure vehicles
ThermHex is an excellent choice for van conversions, motorhomes and caravans, helping to reduce the weight of walls, floors and ceilings. These leisure vehicles benefit from honeycomb core sandwich panels thanks to their superior thermal insulation and lightweight build, which is essential for efficiency and comfort on the road.
CNC capabilities for sandwich panels
At Panel Systems, we can offer a wide range of bespoke manufacturing services, providing a solution tailored to your project. All our panels can be cut, CNC machined and drilled to bespoke shapes and sizes through use of our extensive 3 & 5 Axis CNC capabilities.
Our skilled CAD/CAM team is also on hand to bring your ideas and designs to life, advising on specific cutting details, suitable materials and capabilities.
For more information on ThermHex core sandwich panels, contact our team today on 0114 275 2881
or email sales@panelsystems.co.uk
