3D|Core™

What 3D|CORE™ variants are available and how do they differ?

The 3D|CORE™ sandwich cores are based on two different foam core materials: extruded polystyrene foam (XPS) and PET foam. PET is available exclusively in the hexagonal structure, which provides very uniform load distribution and outstanding drapeability for complex composite components. XPS is offered in three different honeycomb structures: Hexagon, Rhombus, and perforated. The Hexagon and Rhombus structures offer excellent flexibility and formability due to their geometric design, while the perforated variant is optimized specifically for the requirements of the vacuum infusion process and RTM. These diverse structural variants enable optimal adaptation to various lightweight applications and processing methods.
 

What technical advantages does 3D|CORE™ offer?

With a density of approximately 45 kg/m³, the XPS foam core impresses with an excellent strength-to-weight ratio, enhanced by low resin uptake and small cell size. The PET variants also provide higher thermal resistance and are well-suited for demanding, mechanically stressed components. The special honeycomb construction ensures excellent fiber impregnation, optimal resin distribution, and improved shear and bending strength. The high drapeability and flexibility of the 3D|CORE™ structural cores facilitate processing in the vacuum injection process as well as in IMC/MTI® procedures, reducing production time and material consumption.

For which applications is 3D|CORE™ especially suitable?

The versatile 3D|CORE™ core materials are ideal for use in mold making, boat building, automotive body construction, and sports equipment manufacturing. They are also employed in the rail vehicle industry and other industrial lightweight projects. When combined with glass fiber or carbon fiber laminates, extremely lightweight yet highly stable components with enhanced compressive and shear strength are created. The structural variety of Hexagon and Rhombus honeycombs in XPS as well as the hexagonal structure in PET allows for flexible use in different lightweight components, with the specialized structures providing excellent adaptation to complex geometries.

How does 3D|CORE™ support sustainable and efficient production?

Thanks to the optimized combination of a lightweight foam core structure and reduced resin uptake, 3D|CORE™ enables significant material savings and improved cost and time efficiency in manufacturing. The high form flexibility allows easy adaptation to complex component shapes, which is especially advantageous in the vacuum infusion process or RTM procedures. The range of variants — XPS in Hexagon, Rhombus, and perforated structures, as well as PET in various thicknesses — makes 3D|CORE™ a flexible and sustainable core material for modern composite lightweight construction. HP-Textiles thus offers an economical and high-performance solution for various sandwich components with an optimal strength-to-weight ratio.