Core Materials
Sandwich materials for high-performance lightweight structures
What makes sandwich materials a key technology in composite lightweight design?
Sandwich materials play a crucial role in fiber-reinforced lightweight construction. By combining reinforcement fibers (e.g., glass or carbon fiber) with a lightweight sandwich core like PET foam, XPS, or polyester, the result is structurally stable, yet weight-optimized composite components. These typical sandwich structures offer significant advantages in terms of bending strength, compressive performance, and shear resistance without increasing the component’s mass. Such hybrid sandwich solutions allow targeted load distribution while meeting high standards of thermal and chemical resistance. The reduction in resin and fiber usage compared to solid GRP laminates leads to cost savings, improved sustainability, and ideal processing efficiency in vacuum infusion or RTM processes.
Why is 3D|CORE™ ideal for complex component geometries?
The 3D|CORE™ sandwich material is based on a structural reinforcing foam core (SVS) with a hexagonal honeycomb structure, connected via fine webs that allow high drapeability and uniform load transfer. This geometry enables use in three-dimensionally formed lightweight components, commonly required in boatbuilding, sports equipment manufacturing, automotive construction, and GRP mold making. The 3D|CORE™ material enhances fiber wet-out and enables consistent resin flow, providing substantial advantages in IMC/MTI processes. Its high processing efficiency and reduced carbon input make 3D|CORE™ a cost-effective and sustainable core material for advanced sandwich constructions.
What are the properties of the HP-core core fleece?
The HP-Core core fleece is a versatile, lightweight sandwich material made of expanded microballoons and polyester fibers. It functions as a core material between GRP layers and is ideally suited for epoxy and polyester resin systems. Compared to traditional solid GRP laminates, it enables weight savings of up to 50%, while increasing stiffness. Especially in sectors such as automotive, rail vehicle construction, aerospace, and tool or mold manufacturing, the fleece provides excellent form stability and easy adaptability to contours. Once saturated with resin, the core fleece remains flexible and allows precise shaping, even on complex surfaces. As a sandwich core, it impresses with time savings, material efficiency, and clear economic benefits – making it a core component of modern composite manufacturing.
What are the typical applications of sandwich materials?
Sandwich materials are used wherever high-strength, yet lightweight components are required. Typical applications include boatbuilding, automotive paneling, mold and tool construction, sports equipment manufacturing, and industrial solutions in rail vehicle engineering or for insulating structures. In aerospace, wind energy, and electrical enclosures for composite systems, hybrid sandwich structures with PET, XPS, or polyester cores prove to be highly effective. Their ability to distribute loads effectively also makes them ideal for use in vacuum infusion or resin transfer molding (RTM) processes. In all these fields, sandwich composites provide excellent structural performance at minimal weight, directly enhancing energy efficiency, handling, and production cost-effectiveness. HP-Textiles offers a broad range of core materials suitable for almost all lightweight processing technologies. The sandwich materials category is divided into two high-performance subgroups: 3D|CORE™ structural cores and the versatile HP-Core core fleece.