Foam Core Sandwich Panels Manufacturer

Foam Core Sandwich Panel

Foam core sandwich panels combine a polypropylene honeycomb core with reinforced thermoplastic or fiberglass skins, delivering lightweight structural performance as an alternative to metal, wood, and solid plastics. Core densities range from 60 to 100 kg/m³, providing excellent strength-to-weight ratios with compressive strength from 1.47 to 2.6 MPa and shear strength between 0.4 to 0.68 MPa.

The polypropylene honeycomb core features hexagonal or diamond-cell structures, often laminated with non-woven polyester scrim and polypropylene film barriers to prevent resin intrusion. Skin materials include Continuous Fiber Reinforced Thermoplastic (CFRT) sheets or fiberglass, providing wear-resistant, scratch-resistant surfaces. Panels offer waterproof performance, chemical resistance, and full recyclability.

Available thicknesses range from 3mm to 120mm with widths up to 2.8 meters and lengths to 12 meters. Standard cell sizes vary from 6mm to 16mm. Thermal lamination fuses components without adhesives, ensuring delamination resistance. Further processing includes Computer Numerical Control (CNC) machining, thermoforming, and compression molding. Temperature stability spans -40°C to 80°C with sound dampening exceeding 22 dB attenuation.

Applications span transportation (truck bodies, recreational vehicle interiors, marine decks), construction (partitions, flooring, formwork), and industrial uses (containers, tooling). Surface treatments include glossy, matte, embossed, or painted finishes with optional Ultraviolet (UV) protection through carbon black additives or protective films for outdoor durability.

PET Foam Sandwich Panel

A high-performance sandwich panel combining structural skins with a thermoplastic PET foam core. This material is defined by its superior fatigue resistance and a high service temperature, ensuring excellent durability and mechanical performance under dynamic and thermal loads.

PMI Foam Sandwich Panel

An ultra-high-performance panel featuring a PMI rigid foam core between structural face sheets. It is distinguished by its exceptionally high service temperature and superior mechanical properties, delivering unparalleled strength and stiffness-to-weight ratios for demanding, high-temperature conditions.

PU Foam Sandwich Panel

A high-efficiency insulating panel constructed with a rigid polyurethane (PU) foam core. It is characterized by its industry-leading low thermal conductivity, which provides superior thermal insulation performance and maximum energy efficiency in any temperature-controlled environment.

PVC Foam Sandwich Panel

A versatile composite panel utilizing a closed-cell PVC foam core between durable skins. Its defining characteristics are excellent resistance to chemicals and corrosion, coupled with inherent self-extinguishing fire properties, ensuring safety and longevity in harsh or corrosive environments.

XPS Foam Sandwich Panel

A durable sandwich panel featuring a closed-cell extruded polystyrene (XPS) foam core. Its defining property is extremely low water absorption, which ensures stable, long-term thermal resistance and consistent insulating performance, particularly in wet or high-humidity conditions.

RaxPanel: Leading Foam Core Sandwich Panel Manufacturer

RaxPanel, a leading manufacturer of composite panel solutions based in Hebei, China, brings over 20 years of experience to the production of high-performance Foam Core Sandwich Panels. Our panels feature a unique sandwich structure with a honeycomb core, delivering an exceptional combination of lightweight design, durability, and ease of processing. Fully recyclable and resistant to impact, moisture, and chemicals, they are engineered for diverse applications including:

Logistics
Transportation
Construction
Industrial uses

As a direct manufacturer with in-house R&D and full control over production, we ensure consistent quality and rapid, cost-effective solutions. With a daily output exceeding 1500 m² and a commitment to high-performance, reliable, and eco-friendly materials, RaxPanel serves clients across more than 30 countries. Our expertise and scalable manufacturing capabilities allow us to meet customized requirements efficiently.

Need something different? We’ve got you covered. As a leading manufacturer of composite structures, you can rely on us to provide tailored, high-quality solutions.

Factory Tour
Send Inquiry Today

Other Products You May Like

Building Sandwich Panel

GRP Sandwich Panel

CFRT Sandwich Panel

Frequently Asked Questions

What are the key advantages of RaxPanel Foam Core Sandwich Panels?

RaxPanel Foam Core Sandwich Panels offer excellent features including lightweight construction (density typically 60-100kg/m³), high compressive and bending strength, waterproof properties, wear resistance, low cost compared to metal panels, and are 100% recyclable.

What materials are used in RaxPanel Foam Core Sandwich Panels?

Our panels consist of a thermoplastic skin material - CFRT (continuous fiber reinforced thermoplastic) sheet - and a thermoplastic core material of PP (polypropylene) honeycomb, thermally laminated without adhesives for superior bonding.

What customization options are available for these panels?

We offer customized color, size, thickness, and density options. We also provide CNC processing services, related accessories, CKD/SKD services, and reliable packaging solutions to meet your specific project requirements.

What surface treatments are available for the panels?

We offer multiple surface treatment options including glossy/matte finishes, embossed textures, and custom painting. Protective films can be applied to enhance anti-scratch performance and provide aesthetic effects.

What are the typical applications for these sandwich panels?

Our panels are widely used in box bodies (dry cargo boxes, RV bodies, flight cases), flooring (RVs, yachts, trucks), sports products, building formworks, solar back panels, countertops, baffles, and partitions across multiple industries.

Are RaxPanel Foam Core Sandwich Panels suitable for outdoor use?

Yes, our panels feature UV protection treatment with good weather resistance, allowing them to fully adapt to outdoor environments. The polypropylene material provides excellent resistance to water, chemicals, and corrosion.

What are the maximum dimensions available for these panels?

Our panels are available in thicknesses from 6.0mm to 120mm, with maximum width of 2.8m and maximum length of 12m, providing flexibility for various project requirements.

What customization options are available for large-volume OEMs integrating panels into their production lines?

We offer extensive customization including tailored color, size, thickness, and core density to meet specific design and performance requirements. Our panels can be provided with CNC processing services to eliminate the need for reprocessing, and we supply related accessories along with CKD/SKD services. Custom surface treatments such as glossy, matte, embossed, or painted finishes are available, and we ensure reliable packaging solutions for safe transportation.

How do you support distributors and wholesalers with inventory and market demand fluctuations?

We maintain a high daily output to ensure product availability and support favorable bulk pricing. Our reliable logistics and packaging solutions help safeguard inventory during transit. We offer marketing support such as product brochures and samples to assist in meeting market demand, and our customizable options allow for flexibility in responding to specific customer requirements.

What technical and installation resources are provided for contractors and construction teams?

We supply detailed technical data including compressive strength, shear strength, and thermal properties, along with guidance on panel workability and durability. Our products are designed for ease of installation, with options for various surface treatments and thicknesses to suit different project needs. Additionally, we provide information on material compatibility and performance in diverse environmental conditions.