Base Panels - Plascore

Your final product begins with a strong foundation.

We offer build-to-print and build-to-specification services. We can manufacture with a focus on aesthetics, performance, functionality, and more. Our team will guide you in selecting the most suitable materials to meet your specific requirements. While we’ve listed some common options below, we’re always open to exploring new materials to ensure your needs are fully met.

Panel Options

Skin Materials

Aluminum
Stainless Steel
High Pressure Laminate
Glass/Epoxy Prepreg
G10 Fiberglass
Carbon Fiber

For other materials, please contact us.

Skin finishes

Clear Epoxy Primer
Mill Finish
Decorative
Powder Coat

For other finishes, please contact us.

Cores

Aluminum (Commercial and Aero/Military Grade)
Stainless Steel
Nomex® (Commercial and Aero/Military Grade)
Kevlar® (Aero/Military Grade)
Polypropylene
Polycarbonate
Foam
Plywood

Adhesives

Commercial grade toughened epoxy
- Cost-effective
Modified Epoxy Film Adhesive
- Multiple weights available
- Can be MIL spec or ASTM certified

Other adhesive types available upon request.

sizes

Thickness: 1/8”-3” standard
Width: 48” and 60” standard
Length: up to 190” standard

For all other sizes, please contact us.

standard panels

Not sure where to start? Our Standard Panels feature proven constructions widely used across many industries. Engineered to support OEM manufacturing, Plascore Honeycomb Panels are offered in custom-cut sizes and shapes, or in standard 48″ x 96″ sheets in a variety of thicknesses. All standard panels are supplied with open edges. For larger applications, our AA3.6-80 and AA5.2-95 panels are available in sizes up to 5′ wide by 12′ long.

AA5.2-95: Epoxy Fiberglass Skin/Aluminum Core

AA3.6-80: Aluminum skin/Aluminum Core

PP5.0-90: Fiberglass Skin/Polypropylene Core

Characteristics

Panel ID	AA3.6-80	AA5.2-95	PP5.0-90	Plywood
High Strength	X	X	X	X
Stiff	X	X	X	X
Low Flammability	X
Finishing	X	X
Salt Environment		X	X
Fuel Environment		X	X
Paintable	X	X	X	X
Chemical Resistance*			X
Lightweight	X	X	X
Machinable	X	X	X	X

Specifications for Standard Honeycomb Panels

Panel Id	Skin	Core	Adhesive
AA3.6-80	.020″ Aluminum with Epoxy Primer	3/8″ Aluminum 3.6#pcf	Commercial Grade Toughened Epoxy
AA5.2-95	.015″ Fiberglass Prepreg	1/4″ Aluminum 5.2#pcf	Epoxy Resin
pp5.0-90	.014″ G10 Fiberglass	.315″ Polypropylene 5.0#pcf	Commercial Grade Toughened Epoxy

Panel ID	Flatwise tensile strength¹		Climbing Drum (Per Unit Width)²		Stabilized Compressive Strength³		Thickness		Weight		Flexural Rigidity (Per Unit Width)⁴
	lb/in²	N/mm²	lbf	N	lb/in²	N/mm²	in	mm	lb/ft²	kg/m²	lb*in²	N/mm²
AA3.6-80	644	4.44	52	231	369	2.54	0.25	6	0.79	3.9	5375	1.46
							0.50	13	0.84	4.1	23291	6.32
							0.75	19	0.94	4.6	46858	12.72
							1.00	25	1.01	4.9	71654	19.45
AA5.2-95	998	6.88	92	407	749	5.16	0.25	6	0.53	2.6	1673	0.45
							0.50	13	0.62	3.0	7756	2.11
							0.75	19	0.72	3.5	17776	4.83
							1.00	25	0.82	4	30231	8.21
PP5.0-90							0.50	13	0.57	2.8	6259	1.70
							0.75	19	0.67	3.3	13015	3.53
							1.00	25	0.76	3.7	20117	5.46

Disclaimer: Values listed are ‘typical values’.
¹ Data obtained through testing in accordance with ASTM C 297
² Data obtained through testing in accordance with ASTM D 1781 with specimen widths of 3″
³ Data obtained through testing in accordance with ASTM C 365
⁴ Data obtained through testing in accordance with ASTM C393/C 393M-06 at a Four-Point,
Quarter-Point Loading configuration and a span of 20″, width 3″, except 0.25″T @ 1.5″ width

Thermoplastic Panel

Made with Plascore Polypropylene Honeycomb core and a variety of reinforced Polypropylene facing laminates, these panels offer a lightweight and structural composite sandwich structure.

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Product Spotlight

pickleball

Plascore manufactures in the USA both Polypropylene (PP) Honeycomb core and Composite Panels with Carbon Fiber (T700) or Fiberglass Facings and PP Honeycomb core.

Plascore uses a High Impact Copolymer Polypropylene that provides Quality, Durability, Power and Control to your paddle.

Available in a variety of cell sizes, density, thicknesses, and cut to size for your specific requirements.

Polypropylene Honeycomb

4 and 5 pcf density with 8 and 10 mm cell sizes
Multiple Thickness, Width, Length or cut to Size/Shape to your requirements
LEARN MORE

Laminated Composite Panels

110 Panel: T700 Carbon Fiber facings with Polypropylene Honeycomb core
90 Panel: Fiberglass Facings with Polypropylene Honeycomb core
Multiple Cell Sizes, Density, Thickness or cut to Shape to your requirements
Other Materials available upon request