Innovative Polypropylene Honeycomb Core

ThermHex is a polypropylene honeycomb material which is used as a core material for sandwich panels and lightweight components.

Watch our video on ThermHex and its uses


The core material is used to manufacture lightweight but incredibly strong panels, making it ideal for a wide range of applications including automotive, truck bodies, shipbuilding, OEM, industrial equipment and caravan manufacturing

Can be ordered in standard and bespoke sizes exclusively from Panel Systems Ltd.

Manufactured to order in Sheffield, from stocked materials


ThermHex is an innovative polypropylene honeycomb core material primarily used in the production of lightweight sandwich panels and fibreglass components. At our two manufacturing plants in Sheffield, we have the latest 3 & 5 axis CNC equipment and offer customers the ability to manufacture bespoke sandwich panels with ThermHex as the core.

ThermHex can be ordered in standard and bespoke sizes exclusively from Panel Systems Ltd. ThermHex sheets are available in thicknesses from 3.5mm to 28mm with cell sizes from 3 mm to 9.6 mm. Standard thicknesses are: 3.5, 6, 8, 10, 12, 15, 18, 20, 25 and 28 mm. ThermHex is available in the standard sheet size of 2500mm x 1200mm or can be cut to size, if required. Bespoke sheet sizes up to 7500mm long are available subject to minimum production quantities.

We can also bond the material to a range of facing materials, such as metals, plastics, timber and decorative laminate to offer benefits in terms of aesthetics, strength and lightness. This includes bonding with both polyurethane based adhesives. We have an extensive range of vacuum and platten presses for the manufacture of composite panels. Our fabrication capability includes three CNC routers, metal shearing and folding, aluminium welding and hot-wire foam cutting.


ThermHex is produced using an innovative, patented process which ensures rigidity in terms of its mechanical strength and stability. ThermHex sheets are resistant to chemicals and moisture and therefore offer durability and longevity. The material is 100% recyclable, as part of ensuring ethical and sustainable sourcing of materials.

ThermHex sheets are finished with a polypropylene barrier film. This film avoids the resins or adhesives to ingress into the open cells during converting and in this way assures stable mechanical properties in the finished part. At the same time, the quantity of resin / adhesive needed for processing is kept to a minimum. The second standard surface finish is a PET non-woven material, which enables easy bonding of various types of skin materials with all common adhesives.

ThermHex is produced at a standard density of 80kg/m3. For applications with lower requirements to compression strength, ThermHex offers a lighter core with a density of 60kg/m3.


ThermHex is a revolutionary material that has two very specific properties – being both lightweight and strong. Made from a Polypropylene (PP) honeycomb, it is suitable for a wide range of applications including automotive, truck bodies, the marine industry, OEM, industrial equipment, water jet cutting, caravan markets, plus many more.

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

Tel: 0114 275 2881
Fax: 0114 278 6840


For ThermHex enquiries, contact us on 01909 774 914. Alternatively, please submit your enquiry through to

Frequently asked questions

Can I buy ThermHex as a panel?2023-08-02T10:26:03+01:00

You may purchase ThermHex from Panel Systems as a sheet; however, this is not a complete panel with facing materials. To discuss facing options with ThermHex as the core, please contact our ACP division on 0114 249 5635 or send an email with your requirements through to

Is ThermHex a complete panel?2023-08-02T10:25:29+01:00

No, ThermHex is not a complete panel. ThermHex is a core material that is suitable for having other materials bonded to the faces resulting in a complete panel.

Is ThermHex ready to use on its own?2023-08-02T10:26:22+01:00

ThermHex on its own can be used for resin fibre hand lay-up. When using as part of a sandwich panel, facing materials would normally be bonded to the inner and outer faces of the ThermHex core. There are multiple materials that may be used as facings including but not limited to aluminium, steel, plastics, GRP, timber, ABS and decorative laminate.

What applications is ThermHex suitable for?2023-08-02T10:26:54+01:00

When used as the core material in a complete panel, ThermHex may be used for a variety of applications including but not limited to, wall panelling, floating floors, trucks/trailer bodies, ambulances, and boat deck reinforcement. Panel Systems are primarily equipped for large quantity custom orders; to discuss your requirements with a salesperson, please contact us on 0114 249 5626 or send an email through to

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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