The Ultimate Guide to Buying the Best Honeycomb Core Panel

Aluminum honeycomb cores were initially used for aerospace applications because of their strong, reliable structure made from low-cost and soft materials. Aerospace-grade epoxy adhesive is used and evenly applied by machine to the aluminum foil in specific order and frequency, and the foils are stacked and hot-pressed to create a block before the honeycomb slices are cut and left to expand. If you’re looking to use a honeycomb core panel for your construction project, you may be wondering how and where to start. Here’s a guide to help you with that: 

Your options

Reputable manufacturers of honeycomb core panel products offer them in two types, which are classified according to cell size. That’s regular and micron-aperture. By definition, cells that are less than or equal to 1/5” have a micro-aperture core. They are suitable for applications like filters, machinery, and lighting. Cells that are over 1/5” are regular sized and ideal for marine, interior fit-out construction, and transportation.

Identify your application

Honeycomb core panels can be supplied in different types to suit every application. They can be raw blocks, fully expanded, or unexpanded slices. Although there are other materials used to build honeycomb core panels, aluminum is a preferred material for its high strength and low weight, and versatility. Its properties can be controlled by varying cell size and foil thickness.

Use with caution

The honeycomb core panel may be known for its excellent mechanical properties and low price, but it must be used with caution in certain applications, like large marine structures. That’s because there’s a chance that the material will corrode in saltwater environments. In that case, the honeycomb must not be in direct contact with the carbon skins to prevent galvanic corrosion caused by conductivity. You should also ask the manufacturer for special treatments that can help make the material more reliable and resistant to environmental stress.