Understanding Honeycomb Panels

What is a Honeycomb Panel?

Typically 5 layers: Skin, adhesive, honeycomb core, adhesive, skin. Materials with high tensile and compression strength are best suited to being skins, i.e. aluminum, steel, fiberglass. Adhesive varies widely by application: high strength, high temp, low temp, etc.

Honeycomb Core: A variety of honeycomb cores are available per design requirements.



How Does a Honeycomb Panel Achieve Its Strength?
honeycomb panels strengthHoneycomb panel strength works much like an I-Beam, with the core being the vertical element and the facing being the flange, working together to create high shear strength. Like an I-beam, greater distance between skins (thicker core) will create greater strength.

  • High strength skin reduces risk of tensile failure.
  • Many cells reduce risk of buckling failure.
  • Smaller cells reduce risk of climbing crush or peel failures.
  • Core orientation and density can reduce shear failure.


Stiffer and Lighter than Single Sheet Laminate

The stiffness of Plascore Honeycomb Panels allows the end user to utilize less material and reduce weight. Stiffness increases exponentially compared to single sheet material. The use of honeycomb core(s) creates a dramatic increase in stiffness with very little weight gain.

How is Stiffness Affected by Changing Core Thickness?
honeycomb panel advantages

Relative Stiffness

As shown below, when all 3 structures have equal weight, height and material, honeycomb panel has a stiffness 264% higher.

Honeycomb Panels Relative Stiffness


Light, Strong, Tough, Cost-Effective

Plascore Honeycomb Panels are a high-strength, lightweight material that provide efficient mechanical performance. Our lightweight panels are an excellent alternative to monolithic materials (e.g., solid aluminum, wood and steel) as well as panels with traditional core materials such as plywood, balsa, and foam.

Available in a wide range of sheet sizes and facings, our honeycomb panels are designed for ease of use in many common applications and processes. They can be engineered to meet specific requirements for strength and stiffness. Plascore Honeycomb Panels are used
in many situations that require elevated core shear, compression and adhesion performance.

A World of Applications

Building Products
Plascore Honeycomb Panels provide a flat, stiff, stable structure for use in building as a backing material to metal, glass, stone, and other decorative surfaces. Uses include wall cladding, ceilings, canopies, and elevator interiors.

Plascore Honeycomb Panels offer elevated mechanical properties; moisture, chemical and impact resistance; as well as vibration dampening. The result is improved performance in doors, platforms, fixtures, and custom furniture among others.

Ground Transportation
Plascore Honeycomb Panels provide a lightweight solution for use in rail, automotive, truck, trailer, recreational vehicles, racing, and also military and specialty vehicles. Applications include walls, doors, floors, ramps, ceilings, bulkheads, seating, and shelves.

Marine & Recreation
Plascore Honeycomb Panels offer a high strength-to-weight ratio that satisfies the demands of many applications. Sporting goods, boat decks, partitions, hatches, and doors are just a few examples.

Please refer to the Panel Design Questionnaire and contact us with your requirements.

Panel Design Questionnaire:

Online Form:
Panel Design Questionnaire


Panel Design Questionnaire (318.0 KiB)

Honeycomb Panels Brochure:


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