Honeycomb sandwich panels are composite structures consisting of a lightweight honeycomb core bonded to high-strength face sheets. This configuration provides high bending stiffness, load capacity, and structural stability while maintaining low weight. They are widely used in construction, transportation, industrial equipment, and engineered structures where lightweight performance and strength are both required.
In engineering practice, honeycomb sandwich panels are configurable systems rather than fixed products. Core materials, face sheets, and bonding methods can be selected according to project needs. Chalco supplies multi-material solutions including aluminum, aramid (Nomex), and steel honeycomb cores, combined with aluminum, glass fiber, carbon fiber, or stone panels, delivered as finished panels to meet diverse structural and processing requirements.
Chalco honeycomb sandwich panel material and structural options
Honeycomb sandwich panels can be configured with different face sheets, core materials, and bonding methods to meet varying strength, weight, environmental, and processing requirements. Chalco provides multi-material structural solutions, supporting both standard and customized combinations for engineering applications.
Face Sheets Material Options
Metal panels: Aluminum, stainless steel and other structural metals
FRP/GRP panels: Corrosion-resistant, electrically insulating composites
Carbon fiber panels: Lightweight with high stiffness
Honeycomb Cores Options
Aluminum honeycomb: Mature structure with broad applicability
Nomex (aramid) honeycomb: Lightweight, high-performance core
Thermoplastic honeycomb: Environment-resistant and easy to process
Composite and bonding methods
Structural adhesive composite
Dedicated bonding system for composite materials
All-metal structure with optional brazing composite method
Size and structural configuration
Supports common sheet metal sizes
Thickness, structure, and panel type can be customized according to project requirements.
Chalco Finished Honeycomb Sandwich Panels - Hot Selling Product Types
Chalco offers a variety of pre-fabricated honeycomb sandwich panels with proven structural configurations, combined with project-based customization capabilities, to meet the structural performance, dimensional specifications, and processing adaptability needs of different industries.
Pre-fabricated honeycomb sandwich panels are available in standard sizes (e.g., 48 × 96 inches) and can be customized to project requirements in terms of size and panel type. For large-scale engineering applications, solutions with overall panels up to approximately 5 feet × 12 feet are available.
Thickness: Standard range 1/8"–3", different thickness combinations can be configured according to structural requirements.
Width: Standard width is typically 48 inches / 60 inches.
Length: Standard sheet material can be up to 190 inches long.
Aluminum Honeycomb Sandwich Panels
Aluminum honeycomb sandwich panels are one of the most mature and versatile honeycomb sandwich structures. These products use aluminum honeycomb core material as their core, and are integrally molded with metal or composite panels. They offer a balanced performance in terms of structural stability, dimensional consistency, and engineering adaptability, making them suitable for various engineering scenarios.
Chalco offers aluminum honeycomb sandwich panels with adhesive-bonded and brazed composite structures, and supports subsequent processing such as punching, bending, and forming, supplying them as finished honeycomb sandwich panels.
Typical application areas:
- Building curtain wall and decorative enclosure system
- Vehicle floor, side walls and partition structure
- Industrial equipment enclosures and structural panels; ship and marine internal structures
Chalco Advanced Aluminum Honeycomb Sandwich Panels
Perforated honeycomb sandwich panel
Embossed honeycomb sandwich panels
Arc-shaped honeycomb sandwich panel
Carbon Fiber Honeycomb Sandwich Panels
Carbon fiber honeycomb sandwich panels use carbon fiber composite materials as the face panel, which are integrally molded with aluminum honeycomb or aramid (Nomex) honeycomb core materials. They are suitable for engineering applications with higher requirements for lightweighting, structural rigidity and performance stability.
This type of honeycomb sandwich panel can be flexibly configured with honeycomb core material type and carbon fiber layup method according to project needs, and is provided in the form of finished sandwich panels, supporting project-based customization and bulk supply.
Typical application areas:
- Aerospace and high-performance engineering structures
- Lightweight structural components that are sensitive to weight
- High-end customized composite material structure
Chalco Advanced Carbon Fiber Honeycomb Sandwich Panels
Carbon Fiber + Aluminum Honeycomb Sandwich Panel
Carbon Fiber + Nomex Honeycomb Sandwich Panel
Composite Carbon Fiber Honeycomb Sandwich Panel
FRP/GRP Honeycomb Sandwich Panels
FRP/GRP honeycomb sandwich panels use glass fiber reinforced composite materials as the face panel, which are integrally molded with the honeycomb core material. They combine lightweight, corrosion resistance and environmental adaptability, and are widely used in industrial and transportation fields.
By combining different panel thicknesses and honeycomb core structures, this type of honeycomb sandwich panel can achieve a balance between structural performance and cost control, making it suitable for various engineering environments.
Typical application areas:
- Vehicle body and box structure
- Industrial equipment and protective enclosures
- Marine engineering and applications in humid and corrosive environments
Chalco Advanced FRP / GRP Honeycomb Sandwich Panels
FRP-Faced Aluminum Honeycomb Sandwich Panel
FRP-Faced Nomex Honeycomb Sandwich Panel
Stainless Steel–Faced FRP Honeycomb Panels
Nomex, Thermoplastic & Special Honeycomb Sandwich Panels
Aramid/thermoplastic and special structure honeycomb sandwich panels
(Nomex, Thermoplastic & Special Honeycomb Sandwich Panels)
For special working conditions or customized engineering needs, Chalco offers honeycomb sandwich panel solutions based on aramid (Nomex) honeycomb, thermoplastic honeycomb, and other special structural core materials. These products are typically configured in terms of structure and materials according to project requirements and are suitable for applications with special requirements for performance, environmental conditions, or functionality.
Typical application areas:
- High-performance and weight-sensitive structures
- Special environments or non-standard engineering projects
- Customized structural and functional components for projects
Advanced product display
Nomex honeycomb sandwich panel
Thermoplastic honeycomb sandwich panel
High-strength honeycomb sandwich panels
Edge Structures & Joint Configurations
In engineering applications, the edge structure and connection method of honeycomb sandwich panels directly affect the overall strength, installation method, and reliability. Chalco can provide a variety of edge and connection structure configurations to meet structural and assembly requirements.
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Co-constructed edge structure
The edge structure is formed simultaneously during the composite molding stage of the honeycomb sandwich panel. The edges are integrated with the panel and honeycomb core, which helps to improve the overall strength. It is suitable for engineering applications with requirements for load-bearing capacity and installation stability.
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Post-processing edge sealing
After the sheet material is formed, the edges of the honeycomb structure are sealed. This process improves edge protection and reduces the exposure of the honeycomb structure. It is commonly used in applications where durability and service life are critical.
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Blind snap and embedded structure
Pre-installed installation or connection points are located within the honeycomb sandwich panel. This allows for concealed fastening, balancing structural strength with a clean appearance. Suitable for structural designs requiring assembly but where exposed connectors are undesirable.
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Snap-fit and plug-in structure
The boards are connected via snap-fit or plug-in methods. This facilitates quick installation and disassembly, making it suitable for modular applications. It is commonly used in engineering systems where high assembly efficiency is required.
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Internal and local structural reinforcement
Localized reinforcement design for specific stress or installation areas. This can improve structural stability without significantly increasing weight. Suitable for locations with concentrated loads or localized installation requirements.
Manufacturing & Project Capabilities
Chalco offers engineering-grade processing and project configuration support for finished honeycomb sandwich panels, enabling the panels to directly meet structural installation and application requirements.
CNC Machining & Forming
CNC cutting and size customization
Irregular openings and functional cut-outs
Bending and structural forming
CNC Machining & Forming
Mill finish or decorative surface
Epoxy edge protection
Powder coating (wear and weather resistant)
Component Integration
Brackets, hinges, and connection parts
Doors, openings, sealing and insulation
Glass panel integration or kit packaging
Project-Oriented Cooperation Fields
Leveraging its processing capabilities for honeycomb sandwich panels and its experience in project integration, Chalco participates in various engineering applications through project collaboration, providing customers with collaborative support from material selection and structural configuration to processing and delivery.
Aerospace and high-performance engineering structures: for engineering projects with high requirements for lightweight, high strength and structural reliability.
Building decoration and enclosure system engineering: applicable to project-based applications of curtain walls, decorative panels and functional enclosure structures.
Transportation and vehicle structure projects: serving the structural weight reduction and modularization needs of rail transit, special vehicles and transportation equipment.
Industrial equipment and complete system projects: Support the structural integration of engineering systems such as equipment housings, platforms, and functional modules.
Shipbuilding and marine engineering projects: Applied to marine engineering scenarios that require corrosion resistance, structural stability and long-term service performance.
Engineering Differentiation & Key Configuration Considerations for Honeycomb Sandwich Panels
- Asymmetric structural requirements: Supports different face sheet materials on each side for asymmetric load or functional designs.
- Bonding method selection: Provides adhesive or brazed construction, matched to service conditions.
- Large-panel flatness control: Experienced in medium and large-size panels, with stability considered during configuration.
- Panel–core stiffness coordination: Optimizes face sheet material, thickness, and core type for balanced structural performance.
- Post-processing impact: Supports cutting, bending, and drilling, with feasibility evaluated at the design stage.
- Non-standard project coordination: Integrates material, structure, and fabrication options on a project basis.
Choose Chalco for Honeycomb Sandwich Panels
In engineering projects, the selection of honeycomb sandwich panels often involves a comprehensive confirmation of material systems, structural configurations, and processing methods, rather than the selection of a single product specification. Chalco provides project-oriented support for honeycomb sandwich panels, assisting in material combination assessments, structural form confirmation, and processing feasibility communication to help reduce uncertainties during the selection and implementation process.
Whether for standard structural configurations or customized engineering needs, Chalco can coordinate sample verification and batch supply arrangements based on actual application conditions, providing stable and controllable supply support for project implementation.
Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.
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