Panel Core Materials

Panel Core Materials

PP -polypropylene honeycomb

PP honeycomb HEX core is one of our most widely used high performance honeycomb core materials; chosen for its cost competitiveness, excellent strength to weight ratio (the best of all core materials) and bonding characteristics. PP is 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.

PC – Polycarbonate

This is a high performance twin wall hollow core made of polycarbonate material at high temperature. There is various cell types e.g. honeycomb, delta etc PC is a very strong and resilient thermoplastic material. It has excellent properties such as heat preservation, flame retardant, UV protection, wind and rain resistance, light weight, sturdy and durable, and good aging resistance.

AH - Aluminium Honeycomb

Aluminium Honeycomb core is used in applications where reducing weight whilst maintaining or improving the strength of a panel is of key importance. AH material comes in a range of thicknesses available all offering fantastic strength to weight properties and is ideal for hygienic environments as they are non-shedding. An AH core produces a panel with enhanced stiffness and stability whilst still one of our lightest weight solutions perfect for vehicle body, wall, ceiling and façade applications.

Plywood Core

Various grades, thickness and types of plywood products are available to be incorporated into panel compositions. Any specification can be sourced hardwood, marine, Birch, Poplar core etc to meet client specific performance criteria. FastPanel technical can advise best product composite suited to particular applications.

insulation cores

EPS Expanded polystyrene

EPS is manufactured using beads of foam within a mould, heat or steam is then applied causing them to expand and fuse together. EPS is made of 98% trapped air and only 2% plastic, This process produces a closed cell structure, not a closed cell insulation board, due to voids that can occur between the beads. XPS is a rigid foam insulation made from polystyrene with lambda values of around 0.034 – 0.038 W/m·K.

XPS Extruded polystyrene

XPS is a high performance rigid insulation and unlike EPS is manufactured using a process of extrusion. This continuous process results in a closed cell structure with a smooth skin on the top and bottom of the board. It is a structural insulant which significantly denser than most insulation and is available in various grades for specific applications requiring high loadings and greater compressive strength. Its closed cell structure also resists both moisture and water vapour ingress. XPS offers lambda values of around 0.029 – 0.038 W/m·K.

RPET Recycled PET

Recycled PET foam is a thermoplastic core material suitable for a variety of composite panel applications to increase performance and reduce weight. Like other heavy-duty foams RPET offers high strength-to-weight ratio, reduced weight, and good thermal insulation. RPET foam has 100% recycled polyethylene terephthalate as the base raw material in the manufacturing results in a RPET insulated core that offer significant savings in CO2 emissions compared to other structural foam core materials. RPET offers lambda values of around 0.034 – 0.046 W/m·K.

Mineral Fibre Wool

Mineral wool solutions, Rock and Glass based are high performance insulations offering A1 non-combustible solutions to provide the perfect solution for where smoke and fire safety is required.  Mineral fibre cores also offer superior acoustic performance over other insulation core materials. Mineral wool is available with lambda values as low 0.032 W/m·K depending on the panel build up.

PU & PIR Polyisocyanurate Foam

Most rigid polyurethane foam insulations in the UK and Ireland are now manufactured as PIR which achieve low thermal values and a better resistance to fire than some foams making them ideal for certain panel applications.

Phenolic insulation

Phenolic insulation is a rigid insulation with a closed-cell structure that can achieve a lambda value as low as 0.018 W/m·K.