Perforated panels
Micro-perforated face skin over the core with an acoustic fleece gives sound absorption for ceilings and transport interiors.
Panel guide
Honeycomb Sandwich Panel
A honeycomb sandwich panel is two thin facing sheets bonded or brazed to a honeycomb core, a build-up that gives the stiffness of a much thicker solid plate at a fraction of the weight. The facing material decides appearance, durability and impact resistance; the core decides shear strength and weight. Metline supplies aluminium-faced honeycomb panels and aluminium honeycomb core for panels with other facings, cut to size, worldwide.
- Facings
- Aluminium sheet, bare or coated
- Core
- 3003 / 5052 / 5056 aluminium
- Standard format
- 1220 × 2440 mm (4 × 8 ft)
- Thickness
- About 3 – 75 mm
What makes up a honeycomb sandwich panel
Every honeycomb sandwich panel has the same three layers: a facing on each side and a honeycomb core between them, joined by adhesive or by brazing. Change any one layer and the panel changes character, which is why the same word covers a 6 mm interior ceiling panel and a 50 mm aircraft floor.
| Layer | Common choices | What it controls |
|---|---|---|
| Facings (skins) | Aluminium 3003, 5052, 5005, 6061; coated or anodised. Also CFRP, GFRP, stone veneer, laminates | Bending strength, surface finish, impact and scratch resistance |
| Core | Aluminium honeycomb (3003, 5052, 5056); aramid, thermoplastic or paper in other markets | Shear strength, compression, weight, temperature limit |
| Joining | Epoxy film, two-part epoxy or polyurethane adhesive; vacuum brazing for all-aluminium panels | Bond durability, fire behaviour, maximum temperature |
| Edges and inserts | Extruded aluminium edge profiles, folded skins, potted inserts | Sealing, fixing and load introduction |
Bending stiffness of a sandwich comes mainly from the facings and the distance between them. For two equal facings of thickness tf and modulus E, separated by a distance d between their centre lines, the bending stiffness per unit width is approximately D = E × tf × d² / 2. Doubling the core thickness therefore roughly quadruples stiffness, while the weight hardly changes.
Facing options compared
| Facing | Strengths | Limitations | Typical uses |
|---|---|---|---|
| Aluminium sheet (mill, anodised, PVDF or polyester coated) | Durable, flat, recyclable, non-combustible metal; wide colour range | Dents under hard impact | Facades, ceilings, partitions, vehicle bodies, cleanrooms, platforms |
| Brazed aluminium | No adhesive, no outgassing, higher temperature tolerance | Higher cost, size limited by furnace | Cleanrooms, ovens, vacuum and semiconductor equipment |
| Carbon-fibre (CFRP) | Highest stiffness per weight | Cost; needs insulating ply against aluminium core | Aerospace, motorsport, optical and robotic structures |
| Glass-fibre (GFRP) | Electrically insulating, corrosion-proof, economical composite | Lower stiffness than CFRP or aluminium | Truck bodies, marine interiors, chemical environments |
| Stone veneer | Natural stone appearance at a fraction of the weight | Brittle surface; edge detailing critical | Cladding, lift interiors, furniture |
Metline supplies the aluminium in all of these: aluminium-faced panels complete, and aluminium honeycomb core plus aluminium sheet or coil to fabricators who bond their own composite or stone facings. See carbon fibre honeycomb panels, fibreglass honeycomb panels and stone honeycomb panels for those build-ups.
Aluminium honeycomb panel weights
Panel weight is the two skins (2.70 kg/m² per millimetre of aluminium) plus the core (core density × core thickness). The table assumes a 50 kg/m³ aluminium core, a common density for architectural and interior panels; heavier structural cores add proportionally more, and adhesive adds roughly 0.3 – 0.6 kg/m² depending on system.
| Skin thickness (mm) | Total thickness (mm) | Core thickness (mm) | Panel weight (kg/m², excl. adhesive) | 1220 × 2440 mm panel (kg) |
|---|---|---|---|---|
| 0.5 | 6 | 5 | 3.0 | 8.8 |
| 0.7 | 10 | 8.6 | 4.2 | 12.5 |
| 0.8 | 15 | 13.4 | 5.0 | 14.9 |
| 1 | 20 | 18 | 6.3 | 18.8 |
| 1 | 25 | 23 | 6.6 | 19.5 |
| 1.5 | 25 | 22 | 9.2 | 27.4 |
| 1 | 50 | 48 | 7.8 | 23.2 |
Calculated values for guidance. Solid aluminium plate of equal bending stiffness would be several times heavier.
Worked comparison. A 20 mm panel with 1 mm aluminium skins has facing centre lines 19 mm apart, so D ≈ 69 GPa × 1 mm × (19 mm)² / 2 ≈ 12.5 kN·m per metre width. A solid aluminium plate needs to be about 13 mm thick to match that stiffness, and it would weigh about 35 kg/m² against roughly 6.3 kg/m² for the sandwich: more than five times heavier. That ratio, not the absolute weight, is why sandwich panels dominate large flat surfaces in buildings and vehicles.
The same arithmetic shows what the core must do. The skins only work together if the core carries the shear between them without excessive deflection and supports them against local buckling. On short, heavily loaded spans, check core shear strength and shear deflection; a low-density core that is fine for a ceiling can be the weak link in a floor.
Sizes, finishes and special panels
Typical aluminium panel range
- Standard size
- 1220 × 2440 mm (48 × 96 in); 1220 × 3050 and 1500 × 3000 mm common
- Large formats
- Up to about 1500 mm (5 ft) wide and long lengths to order
- Total thickness
- About 3 mm (1/8 in) to 75 mm (3 in)
- Skin thickness
- About 0.5 – 1.5 mm, thicker for floors and platforms
- Core
- 3003, 5052 or 5056; cell 3 – 19 mm; density to suit loads
- Finish
- Mill, brushed, anodised, PVDF, polyester, wood-grain or stone-grain print
Embossed and textured panels
Patterned skins hide minor dents and fingerprints in public interiors.
Curved panels
Roll-bent or formed over over-expanded core for columns, canopies and curved facades.
Cassette panels
Back-grooved and folded edges create trays with hidden fixings for facades and ceilings.
Where honeycomb sandwich panels are used
- Building: facade cladding, soffits, ceilings, partitions, doors and canopies where large flat panels must stay flat.
- Transport: rail floors, side walls and ceilings, bus and coach panels, truck and trailer bodies, lift cars.
- Marine: bulkheads, ceilings, cabin furniture and superstructure linings on yachts and passenger ships.
- Industrial: machine enclosures, cleanroom walls, work platforms, inspection tables and equipment covers.
- Aerospace and defence: floors, interiors, shelters and ground-support equipment with weight limits.
For each sector, the fire and durability rules differ: EN 13501-1 for buildings, EN 45545-2 for rail, IMO requirements for passenger ships and FAR 25.853 for aircraft interiors. Those requirements are met by the complete panel, so state them on the enquiry.
How to order honeycomb sandwich panels
- Describe the useApplication, span and loads, indoor or outdoor exposure, fire requirements.
- Choose build-upTotal thickness, skin alloy and thickness, core alloy and density, adhesive or brazed.
- Set size and finishPanel size or cutting list, finish and colour, protective film.
- Add detailsEdge profiles, folds, inserts, holes and cut-outs on a drawing.
- Confirm documentsMaterial certificates, test reports (ASTM C297, C393 or as agreed) and export packing.
References and standards
- ASTM C393 – Core Shear Properties of Sandwich Constructions by Beam Flexure
- ASTM C297 – Flatwise Tensile Strength of Sandwich Constructions
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate (facing sheet)
- EN 13501-1 – Fire classification of construction products and building elements
- EN 45545-2 – Railway applications: fire protection on railway vehicles, requirements for fire behaviour of materials
Honeycomb sandwich panels: frequently asked questions
How much does an aluminium (aluminum) honeycomb panel weigh?
A 20 mm panel with 1 mm aluminium skins and a 50 kg/m³ core weighs about 6.3 kg/m² before adhesive, or roughly 19 kg for a 1220 × 2440 mm sheet. A solid aluminium plate of equal stiffness would weigh many times more.
What skin thickness should I choose?
0.5 – 0.8 mm for ceilings and light interior panels, 1.0 mm for facades and partitions, and 1.5 mm or more for floors, platforms and panels exposed to impact.
Can the facings be different on each side?
Yes. Asymmetric build-ups, for example a coated face skin and a mill-finish back skin, are common. Very different skins can cause bowing, so keep thickness and material similar when flatness matters.
Are honeycomb panels suitable for outdoor facades?
Yes, with PVDF-coated aluminium skins, a durable adhesive, sealed edges and a fire classification that meets local building rules.
Can Metline supply panels with carbon-fibre or glass-fibre skins?
We supply the aluminium honeycomb core and aluminium sheet for those panels; the composite facings are sourced and bonded by the panel fabricator.
Need honeycomb sandwich panels?
Send thickness, skins, finish, size and quantity. We will confirm the build-up and quote delivered to your site or port.
