Lightweight Sandwich Panels2024-04-18T13:58:31+01:00

Lightweight Sandwich Panels


Innovative Lightweight Panels for Multiple End Uses

In addition to our existing range of thermal insulating panels, we also manufacture innovative lightweight panels for multiple end uses. We offer a range of lightweight, high strength cores including Polypropylene honeycomb, aluminium honeycomb and XPS foam (Extruded Polystyrene). To compliment the cores, our large range of panel facing materials means we can offer a bespoke solution to meet your design and performance requirements.

Here are some examples of lightweight sandwich panel specifications:

White GRP Faces – ThermHex Core
Birch Ply Faces – Ravatherm XPS Core
Birch Ply Faces – ThermHex Core
Lacquered Aluminium Faces – ThermHex Core
Gloss White Aluminium Faces – ThermHex Core


Wide range of lightweight, high strength cores

Bespoke solutions available

Loading calculations upon request

Technical information

Facing options available:

  • Powder Coated Aluminium
  • Anodised Aluminium
  • Plastisol Steel
  • Trespa
  • Equitone Cladding
  • GRP
  • Rockpanel
  • Building Boards
  • PVC
  • MDF
  • ABS
  • Plywood

Core options available:

  • Ravatherm XPS
  • Fibran XPS
  • Siderise Nexus Core (non-combustible)
  • ThermHex Polypropylene Core
  • Phenolic Foam
  • Polyurethane
  • Tancast
  • Plywood
  • MDF
  • Aluminium Honeycomb

No matter what your requirements for lightweight panels are, our expert sales team are happy to help. Be sure to contact us for more information regarding your unique project details. We can also offer loading calculations upon request.


Most of our lightweight panels incorporate ThermHex – a revolutionary Polypropylene honeycomb core. ThermHex is a strong & lightweight material that provides optimal performance in composite sandwich structures where superior mechanical performance is required. The optimised cell size and the specific structure of ThermHex honeycomb cores offer an exceptional surface quality in sandwich components even with very thin skin material layers.

Typical Applications

  • Van conversions and linings
  • Flooring panels
  • Automotive / truck panels
  • Lightweight furniture panels
  • Structural decks
  • Architectural Panels
  • Bespoke applications

Please note:
The information and data shown does not represent exact sales specifications. The features of the products mentioned may vary. The information given has been provided in good faith, however it does not imply any liability, guarantee or assurance of product performance. It is the purchaser’s responsibility to determine whether these products are suitable for the application desired and to ensure that the site of work and method of application conform with current legislation.


All our panels can be cut, CNC machined & drilled to bespoke shapes & sizes utilising our extensive 3 & 5 Axis CNC capabilities. Please forward your CAD drawings for a quote.

Our friendly and knowledgeable team are on-hand to offer expert advice and help.

Tel: 0114 275 2881
Fax: 0114 278 6840


Need help with your project or design?
We’d love to help bring your ideas to life! For additional technical data or assistance in selecting the right materials for your application & performance requirements, please contact us on 0114 249 5635 or email

Frequently asked questions

Can I buy ThermHex on its own?2023-09-18T10:32:18+01:00

ThermHex may be purchased in sheet form on its own, however this material is not suitable to be used as a finished panel.

Is ThermHex a complete panel?2023-09-18T10:32:01+01:00

When bought on its own, ThermHex is not a completed panel and must be bonded to on both faces with another material.

Can ThermHex sheets be cut to size?2023-09-18T10:32:36+01:00

Panel Systems have a range of cutting and machining services on offer to our customers, meaning that sheets of ThermHex can be cut to the dimensions required for your unique project.

What applications are lightweight sandwich panels suitable for?2023-09-18T10:33:00+01:00

There is a wide range of applications that our lightweight sandwich panels may be suitable for, including but not limited to van conversions and linings, flooring panels, automotive / truck panels, lightweight furniture panels, structural decks and architectural panels. To discuss your requirements with a member of our expert team, contact us on 0114 249 5635.

Contact us

Get in touch to find out more about pricing, or to discuss your requirements in more detail.

Get in touch to find out more about pricing, or to discuss your requirements in more detail.

Call us on 0114 249 5626

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