Aluminum Honeycomb Core

As a professional aluminum honeycomb manufacturer, Chalco supplies commercial-grade (3003, 3005, 3104, 3105) and aerospace-grade (5052, 5056) cores for industrial, architectural, marine, and aerospace applications.

Aluminum honeycomb core standards and specifications

Chalco aluminum honeycomb cores not only meet stringent aerospace-grade standards but also comply with specifications for commercial applications. Whether for high-end aerospace structures or cost-sensitive projects in industry and construction, we deliver products that conform to the required standards, ensuring reliable quality and performance.

Introduction to aluminum honeycomb core

Note: Special sizes, dimensions, tolerances, CNC machining, and die-cut dimensions are available upon request.

Aluminum alloy types of Chalco aluminum honeycomb core

Chalco aluminum honeycomb cores are available in both commercial alloys and aerospace-grade alloys, giving you reliable options for cost-sensitive industrial projects as well as high-performance aerospace applications.

Commercial alloys aluminum honeycomb core (3000 series)

Designed for construction, decoration, transportation, and general industrial use, these alloys feature good corrosion resistance, excellent formability, and competitive cost.

3003 aluminum honeycomb core : The most widely used commercial alloy, with excellent corrosion resistance and processability; ideal for curtain walls, interior decoration, and transport applications.

3005 aluminum honeycomb core : Higher strength than 3003, suitable for building and transportation projects requiring greater mechanical properties.

3103 aluminum honeycomb core : Combines good corrosion resistance with formability, often used in decorative and industrial panels.

3104 aluminum honeycomb core : Provides excellent welding and forming performance, suitable for honeycomb structures that require bending or stamping.

Aerospace-grade alloys honeycomb core (5000 series)

Used in aerospace, rail, marine, and defense where high strength, corrosion resistance, and reliability are critical. Fully compliant with international standards such as AMS 4348/4349.

5052 aluminum honeycomb core :Superior corrosion resistance with balanced strength and ductility; widely used in marine, rail, and commercial sandwich structures.

5056 aluminum honeycomb core :High-strength aerospace alloy with excellent long-term durability and corrosion resistance; ideal for aerospace panels, defense equipment, and other demanding applications.

Different aluminum honeycomb core configurations

Beyond the standard hex cell, Chalco offers engineered aluminum honeycomb core layouts to tune stiffness, shear strength, impact resistance, and weight. Choose the configuration that best matches your load path, forming needs, and budget—available for both aerospace and commercial programs.

Chalco featured aluminum honeycomb core types

Chalco offers a wide range of aluminum honeycomb cores, from standard hexagonal and reinforced types to flexible, overexpanded, corrugated, perforated, and CNC-machined configurations, meeting diverse structural and performance requirements.

• Curved Flexible Aluminum Honeycomb Core

  Curved flexible aluminum honeycomb offers better compound curvature formability than standard hexagonal structures. It reduces reverse bending curvature and improves surface conformity. Typical uses include wing leading edges, flaps, engine cowlings, fairings, and doors.

• Spherical Flexible Aluminum Honeycomb Core

  Spherical flexible aluminum honeycomb is designed for parabolic, spherical, and cylindrical structures, meeting extreme curvature requirements. It is widely applied in radomes, ducts, wing leading edges, and stabilizers, especially where multi-directional forming is needed.

• Corrugated Aluminum Honeycomb Core

  Wave-shaped cell configuration delivers lightweight construction with improved directional strength, compression, and bending performance—used for energy absorption, anti-collision structures, and acoustic/vibration control.

• Perforated Aluminum Honeycomb Core

  Micro-perforations allow air and volatiles to vent during bonding or vacuum bagging, improving adhesive wet-out and preventing delamination. Also supports moisture drainage and pressure equalization for aerospace, marine, and architectural sandwich panels.

• Slant Aluminum Honeycomb Core

  Designed with angled cells at 30°, 45°, or 60°, slant aluminum honeycomb is widely used for shielding, airflow diversion, and specialized engineering applications.

• Micro-Cell Aluminum Honeycomb Core

  Features cell sizes ≤6mm with high density and precision, offering excellent stiffness and surface quality for specialized applications.

• CNC Aluminum Honeycomb Core

  Precision CNC machining creates contoured, pocketed, or edge-closed cores with tight tolerances and repeatability. Ideal for complex aerospace fairings, radomes, tooling fixtures, and lightweight structures requiring custom geometry and controlled cell orientation. Click to view Chalco's machining aluminum honeycomb core services

Types of aluminum honeycomb cores by cell size

Chalco can provide two types of aluminum honeycomb cores with different apertures according to different application requirements to meet customers' diverse choices in performance and structure. These two types of apertures are microporous aluminum honeycomb core and regular cell aluminum honeycomb core, each with its own characteristics.

Micro-cellsize aluminum honeycomb core

Microporous aluminum honeycomb cores (cell size <6 mm) are lightweight, high-strength, and offer excellent airflow control, making them widely used in lighting systems, air purification equipment, ventilator filters, photography gear, and laser processing beds.

Aluminum Alloy	3003, 3005, 3104, 3105, 5052, 5056
Cell Size
	1/30"	1/25"	1/15"	1/10"	1/8"	1/6"	1/5"
	0.87mm	1.04mm	1.73mm	2.6mm	3.17mm	3.47mm	5.2mm
Foil Thickness	0.025mm, 0.03mm, 0.04mm			0.04mm ,0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.1mm
Max Size	300*300mm-1000*1000mm			1200*1200mm	1500*1500mm	2000*1600mm	2000*1700mm

Regular cell size aluminum honeycomb core

Regular cell size aluminum honeycomb cores (cell size ≥6mm) are lightweight, high-strength, and versatile, widely used in aerospace and defense, architectural structures, furniture, yachts, and sandwich panel applications.

Aluminum Alloy	3003, 3005, 3104, 3105, 5052, 5056
Cell Size
	1/4"	1/3"	3/8"	1/2"	3/4"	1"
	6.35mm	8.47mm	9.35mm	12.7mm	19.0mm	25.4mm
Foil Thickness	0.04mm ,0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.1mm
Max Size	8000*1700mm

Aluminum Honeycomb Core Surface Treatments

Chalco offers a range of advanced surface treatment processes designed to enhance the bonding strength, corrosion resistance, and long-term durability of aluminum honeycomb cores. Whether for aerospace, marine, or industrial applications, our treatments ensure stable performance under the most demanding conditions.

CR III Corrosion-Resistant Coating

The CR III coating is a proven protective system consisting of a chromate-based conversion layer and an organometallic polymer. The process is applied to the aluminum foil before it is formed into honeycomb, creating a stable chemical bond with the substrate. This ensures long-lasting adhesion, preventing delamination and maintaining both corrosion resistance and mechanical performance over time. CR III corrosion-resistant coating has been specified by the U.S. military for almost 50 years.

• Outstanding corrosion resistance in harsh environments
• Chemical bonding provides durable adhesion
• Meets stringent military and aerospace standards

CR-PAA™ Phosphoric Acid Anodized Coating

The CR-PAA™ process involves anodizing the aluminum foil in a phosphoric acid electrolyte, forming a porous oxide film on the honeycomb surface. This porous layer acts as an excellent "anchor,” allowing adhesives or primers to penetrate and bond more effectively. At the same time, the oxide film itself provides additional corrosion protection for the aluminum.

• Oxide layer tightly integrated with the substrate for long-term durability
• Significantly enhances bond strength for sandwich panel applications
• Superior corrosion resistance in salt spray and marine conditions
• Stable performance under high temperature and humidity

Chalco provides both CR III and CR-PAA™ surface treatment solutions. The former ensures long-term corrosion resistance through chemical conversion coating, while the latter enhances bonding and durability with an anodized oxide film—delivering the optimal performance for aluminum honeycomb cores across diverse applications.

Chalco Aluminum Honeycomb Core Machining Services

Chalco combines advanced engineering and CNC programming to deliver high-precision machining aluminum honeycomb core solutions. With extensive expertise, we can machine aluminum honeycomb into complex contours and special-shaped structures, meeting the demanding requirements of aerospace, marine, defense, and industrial applications.

Precision Machining Capabilities

• 3/5/6-axis CNC machining — Achieve complex geometries with tight tolerances
• Shaping and contour machining — Ideal for aerodynamic and structural surfaces
• Slotting, drilling, and perforation — For acoustic, ventilation, or weight-saving designs
• Cutting and slicing — Provide unexpanded blocks, slices, shaped cores, and edge finishing
• Bonding surface preparation — Ensure optimized adhesion with surface roughening and priming

Typical Applications

• Flap track fairings, spoilers
• Engine nacelles, thrust reverser structures, and bifurcations
• Outer/inner cowling components, barrel structures
• Core details for blocker doors and other lightweight sandwich assemblies

Explore typical aerospace structures built with Chalco aluminum honeycomb cores — flap track fairings, nacelles, thrust reverser components, spoilers, barrels and more.

Aircraft Flap Track Fairing

Engine Nacelle

Inner Fixed Structure Thrust Reverser

Outer Transcowl

Thrust Reverser Bifurcation

Barrel

Flap Track Fairing

Spoiler

Core Detail for Blocker Doors

Chalco Aluminum Honeycomb Core Supply Forms

Chalco offers a wide range of aluminum honeycomb core supply forms, including expanded or unexpanded, full blocks or cut slices, perforated or non-perforated, corrosion treated or untreated, and customized products to meet specific engineering needs.

Expanded Aluminum Honeycomb Core

Ready-to-use expanded aluminum honeycomb sheets for lightweight, high-stiffness panels.

Cut Slice Aluminum Honeycomb Core

Slices cut from blocks; easy to expand to target thickness and size.

Full Block Aluminum Honeycomb Core

Compact unexpanded blocks for cost-effective shipping and flexible downstream processing.

Slant Aluminum Honeycomb Core

Angled cells (30°/45°/60°) for shielding, airflow diversion and special structures.

Micro-Aperture Aluminum Honeycomb Core

Small cell (≤3 mm) aluminum honeycomb for high precision and surface quality.

Ventilation Aluminum Honeycomb

Aluminum honeycomb used for airflow control, ventilation and acoustic paths.

Aluminum Honeycomb Grid Light

Anti-glare aluminum honeycomb grids for lighting and optical control.

Customized Aluminum Honeycomb

Tailor-made aluminum honeycomb: drilled, curved, cut-to-size and shaped parts.

Aluminum Honeycomb Panel

Sandwich panels using aluminum honeycomb core for ultra-light, high-stiffness structures.

Aluminum Honeycomb Core Manufacturing Process

The production of aluminum honeycomb core is a precise and controlled process to ensure high strength, stability, and durability.

• Foil preparation – High-quality aluminum foil is cut, degreased, etched, and surface treated for bonding.
• Adhesive application – Industrial adhesives are applied in precise patterns to define cell size and strength.
• Stacking & pressing – Foil layers are stacked and pressed into solid blocks with uniform bonding.
• Expansion – The bonded block is expanded into a hexagonal honeycomb structure.
• Cutting & shaping – CNC, waterjet, or laser cutting ensures accurate dimensions and optional forming.
• Surface treatment – Final anodizing, coating, or lamination enhances durability and performance.

Aluminum Honeycomb Core Buying Guide

Confirm Key Specifications

• Density: Determines the balance between weight and load capacity. Low density is lighter, high density is stronger.
• Cell size: Common options are 1/8″, 3/16″, 1/4″. Smaller cells provide higher strength and stiffness.
• Thickness: Choose according to your application; both full blocks and cut slices are available.

Choose the Structural Options

• Perforated or Non-perforated: Perforated cores allow ventilation and resin flow, non-perforated cores retain higher strength.
• Expanded or Unexpanded: Expanded cores are ready for bonding, unexpanded cores are compact for transport or secondary processing.
• Corrosion-resistant coating: Recommended for humid or salt-mist environments to extend service life.

Provide Dimensions and Processing Needs

Please specify Length × Width × Thickness when ordering. If you require additional processing such as cutting, chamfering, drilling, or bonding with face sheets, include this information for a customized solution.

Common Applications

• Lightweight sandwich panels: doors, partitions, furniture
• Energy absorption: crash protection, cushioning structures
• Ventilation and filtration: purifiers, ventilator filters
• Industrial & aerospace: laser cutting beds, aircraft cabin structures

Ordering Tips

Prepare the above parameters and application details when requesting a quotation. Our engineering team will recommend the most suitable honeycomb core solution for your project.

Aluminum honeycomb core mechanical properties

3003 aluminum honeycomb core mechanical properties

• Values shown are typical values, tested at 75°F / 23°C.
• Bare Compressive Strength: Compression capacity of the honeycomb core without facing sheets.
• Crush Strength: Stable load sustained after exceeding the ultimate strength, reflecting energy absorption capacity.
• Shear Strength: Load capacity of the honeycomb core in the L direction (long axis) and W direction (short axis).
• Shear Modulus: Indicates stiffness; the higher the value, the stronger the resistance to deformation.

5052 aluminum honeycomb core mechanical properties

• Values: Data shown are Typical Values in US units (psi, ksi).
• Test Conditions: Measurements were taken at 75°F / 23°C and, for some entries, at 350°F / 177°C.
• Disclaimer: These properties are provided for selection guidance only and are not guaranteed.

5056 aluminum honeycomb core mechanical properties

• Units: Compressive strength and shear strength are given in psi, while shear modulus is expressed in ksi.
• Values: Data represent Typical Values, tested at 75°F / 23°C.
• Disclaimer: Values are provided for reference only and are not guaranteed.

Flatwise compressive strength and shear strength of aluminum honeycomb core

The flatwise compressive strength and shear strength of aluminum honeycomb core are key indicators for evaluating its load-bearing capacity and structural stability under stress:

Flatwise compressive strength measures the core's ability to resist deformation when compressed perpendicular to the panel surface, indicating how well it can withstand external pressure without collapsing.

Shear strength reflects the core's resistance to deformation when subjected to forces parallel to the panel surface, affecting its performance under bending or lateral loads.

These properties are critical for applications requiring high strength and stability, such as aerospace, rail transportation, and architectural cladding.

Density (kg/m³)Cell size (mm)Cell size (inch)Foil thickness (mm)Flatwise compressive strength (MPa)Vertical shear strength (MPa)Flatwise shear strength (MPa)

What testing items are available for Chalco's aluminum honeycomb cores?

Chalco's aluminum honeycomb cores undergo rigorous testing, including salt spray, bending strength, compressive strength, tensile strength, and freeze-thaw resistance, ensuring their high quality and durability. These tests validate the core's resistance to corrosion, mechanical strength, and performance under various environmental conditions.

What services can Chalco offer you?

Chalco offers a variety of aluminum honeycomb core alloys, including 3003, 5052, and 5056, suitable for applications in aerospace, rail transportation, construction, and more. We support customized core sizes, including density, cell size, and foil thickness, to meet the unique strength, weight, and compression performance requirements of our clients.

With precise cutting and processing capabilities, Chalco provides services such as fixed-length cutting, perforating, and pre-assembly treatments, helping customers save time and costs in subsequent processing stages. We also offer surface treatments like anodizing and corrosion coatings, enhancing material durability and extending service life.

Chalco is flexible in handling both large-scale projects and small batch orders for trial production, offering fast prototyping and engineering R&D support. Our engineering team is available to assist customers with material selection, structural optimization, and performance parameter verification, ensuring smooth project progress with one-on-one technical support.

All products undergo strict quality inspections before shipment, and third-party testing reports are available. They meet industry standards such as ASTM, ISO, and GB. For customers with specific performance or structural design needs, Chalco provides one-stop solutions, whether for structural fillers, sandwich manufacturing, or functional components.