Frequently Asked Questions

Lightweight honeycomb panels are sandwich panels made from two outer skins bonded to a lightweight core. This construction can deliver high stiffness and strength while keeping overall panel weight low.

• High stiffness-to-weight performance
• Good flatness and dimensional stability
• Reduced component and transport weight
• Good vibration-damping characteristics
• A wide choice of cores, skins, finishes and sizes

The sandwich construction can be considerably lighter than an equivalent solid sheet while retaining useful stiffness. The exact saving depends on the selected materials, thickness, span and loading, so each panel should be assessed against the requirements of the application.

Core options include aluminium honeycomb, paper honeycomb, polypropylene honeycomb and structural foams such as XPS and rPET. Skin materials include aluminium, MDF, plywood, HPL, decorative laminates, GRP, stainless steel, galvanised or primed steel, PVC, ABS and acrylic. Availability varies by panel type.

Thicknesses and sheet sizes depend on the chosen construction. Common sheet formats include 1220 × 2440 mm, 1250 × 2500 mm, 1250 × 3000 mm and 1500 × 3120 mm, with other sizes potentially available subject to material and minimum-order requirements. We will confirm availability for your specification when quoting.

Weight varies according to the core, skins, thickness and overall construction. Some ultra-light constructions can start at around 2 kg/m², while typical aluminium-faced panels may be heavier. Please use the panel comparison guide as an initial reference and contact us for the weight of a specific construction.

Sandwich panels can provide excellent stiffness and strength for their weight. Actual performance depends on the core, skins, adhesive, thickness, span, support conditions and direction of loading. We can help identify a suitable construction for your application.

Applications include vehicle bodies, floors, ramps, doors, furniture, exhibitions, marine and transport interiors, architectural features, partitions, enclosures and many other projects where low weight and useful stiffness are important.

Fire performance depends on the exact combination of skins, core, adhesive and finish. Certain constructions may be available with relevant classifications or certificates. Please tell us the required standard and application so that we can confirm an appropriate tested construction and supporting documentation.

Suitable panels can be specified for outdoor, wet or marine applications when the materials, bonding system, edges, joints and fixings are designed for the environment. Cut edges and penetrations may need to be sealed. We recommend confirming the complete construction with us before use.

Yes. Depending on the construction, panels can be cut and machined, and edge treatments, inserts or local reinforcements can be incorporated. Tell us the finished dimensions, tolerances and fixing requirements when requesting a quotation.

Common approaches include bonded fixings, inserts, edge members, through-fixings and local reinforcement. The right method depends on the panel construction and expected load, so fixing details should be considered as part of the panel specification.

A broad range of functional and decorative face materials can be considered, including metals, GRP, timber-based boards, HPL, plastics and decorative laminates. Some surfaces can also be supplied ready for subsequent finishing. Availability and suitability will be confirmed for the selected panel.

Cost depends on the panel construction, size, thickness, finish, quantity and any processing required. A higher material cost can sometimes be offset by reduced weight, handling, transport or assembly requirements. Contact us for a project-specific quotation.

Minimum-order quantities vary by product and construction. Selected stock products can be purchased through the online shop, where the applicable minimum is shown. Bespoke panels and non-stock materials will be quoted against the project requirement.

Lead times vary according to stock availability, quantity, construction and any processing required. Current availability and an estimated dispatch date will be confirmed when we quote or process your order.

Lower component weight may reduce the material and energy required for handling or transport. Some panel materials can also contain recycled content or be recyclable, depending on the construction, how materials are separated and the facilities available locally. We can help compare suitable options for your project.

Yes. Tell us about the application, span, loading, support and fixing arrangement, operating environment, finish, thickness, sheet size and quantity. We can then help narrow down the available constructions and provide samples or technical information where appropriate.