Composite Panels

Composite panels offer a cost effective solution to further weight reduction of composite parts such as boats, RV’s, and just about any moving vehicle. After the engineers and designers have worked on the vehicles main structure (hull, decks etc.) further weight can be removed in the internal structure such as floor boards, bulkheads and furniture. These components can be engineered to be light, stiff and strong if designed with light weight panels. The weight reduction is normally between 50% and 75% in comparison to traditional materials such as plywood.

A wide variety of sound dampening cores, decorative veneers and cost considerations are available to meet the goals of your project. Core Composites has a wide variety of suppliers and capabilities and can guide you to the most cost effective solution. See our panel listings for some standard panels that have proven to be economically and structurally useful.

Our suppliers use a variety of processes. Most common are hot pressed prepreg or wet preg skins that are directly bonded to the core material. In some cases the temperature limitation of some of the cores (especially low density foam cores) requires that precured composite skins be bonded with room temperature curing adhesives. These are a bit more expensive due to a two step process but often the lower price foam core make these cold pressed panels economically viable.

Basic Panel Offering:

End Grain Balsa Core in 6 lb/ft3 (100 Kg/m3) or 9.5 lb/ft3 (140 Kg/m3) with 12 oz/yd2 (400 gsm) fiberglass skins with either epoxy or polyester resin.

PVC, PET or PE foam core in densities from 4 lb/ft3 (60 Kg/m3) – 8 lb/ft3 (130 Kg/m3) with fiberglass PE or epoxy resin skins.

Polypropylene honeycomb core from 3 lb/ft3 (50 kg/m3) - 5 lb/ft3 (80 Kg/m3) with 1/8” (3 mm) cork bonded to the PP and then 1/8” (3 mm) plywood bonded for excellent sound dampening. Used for doors, bulkheads and other areas where sound suppression is the driver.

Nomex or Aluminum honeycomb cores from 3 lb/ft3 (42 Kg/m3) – 6 lb/ft3 (100 kg/m3) with prepreg epoxy 6 oz/yd2 (200 gsm) or 9 oz/yd2 (300 gsm) skins for the lightest/ stiffest panel.

These honeycombs or foams and balsa cores can also have aluminum or steel skins bonded to them.

Composite skins are not limited to fiberglass. We can have carbon fiber or Aramid fiber skins bonded at a premium price but with further weight reduction and increased stiffness. Normally these fabrics are from 6 oz/yd2 (200 gsm) – 9 oz/yd2 (300 gsm).

Most sheets are 4’ x 8’ (metric) but 5’ x 10’ and custom sized panels may be ordered. Normal thickness’ are from .25” (6 mm) – 1” (25 mm) but thicker cores and skins may be requested. Peel ply on top of the composites skins is available upon request to reduce surface preparation for post bonding or paint. Most of our skins have extremely low porosity for minimal filling and fairing prior to painting.

Core Composites has available a unique line of continuously pultruded Polyurethane foam cored panels with “through the thickness” fiberglass in the “Z” axis that “ties” the top and bottom skins for improved compression and sheer strength. These are available up to 102” wide and from .25” (6 mm) up to 4” (100 mm) thick. These can be made to any shippable length at very competitive prices. They are almost impossible to delaminate.

Below we offer a chart comparing stiffness (four point bending) and weight per ft2 (m2) of some of the more common panels. We have also listed standard plywood weights to compare to.

The cost of these panels start in the $200.00 per/4’ x 8’ sheet range up to approximately $500.00/per 4’ x 8’ sheet range. If you would like decorative veneers, Formica or other special additions we are happy to quote on volumes that will make sense for a set up which is usually a minimum of six sheets.

We look forward to listening to your requirements and then assisting you to find the best solution to meet your needs in a timely manor. Most of our suppliers can ship standard panels in 4 weeks and special orders in 6 weeks. We stock a variety of popular panels used mainly in the Marine and RV business and package for shipments of 3-6 min. panels per package depending upon the thickness.

There are many techniques for bonding, fastening and cutting composite panels. Ask Core Composites for advice when discussing the specific core and skins that you are considering and we will do our best to guide you to the right tools and suppliers.

Thank you for your interest. We look forward to working with you to further reduce your parts weight.