Various industries are seeking lighter, more durable composite panels to improve the energy efficiency of their products. Thermoplastic composite polypropylene honeycomb panels are composite materials different from traditional adhesive honeycomb sandwich panels. They are made of CFRT (continuous fiber reinforced thermoplastic) composite sheets and polypropylene (PP) honeycomb cores by thermal composite processing. Because the thermoplastic resin permeates each other during the heating process, the CFRT sheet and the honeycomb core material are more closely composited and difficult to separate after cooling. This kind of bonding strength cannot be achieved by adhesive alone.

Main Characteristics

Lightweight

The honeycomb structure significantly reduces weight.

High Strength to Weight Ratio

The panels can withstand large loads and remain structurally stable.

Impact Resistance

Due to the energy-absorbing properties of the honeycomb core, the panels can release the impact of external forces.

Chemical Resistance

Thermoplastic materials are absolutely waterproof and resistant to a wide range of chemicals, which contributes to the durability of the panels in harsh environments.

100% Recyclable

Since the skin and core materials are thermoplastic, the panels are recyclable.

Specifications

Facing	Continuous fiber reinforced thermoplastic. (Thickness: 0.7-2.0mm)
Surface Treatment	Glossy, matte, embossed, rough.
Core	PP (Polypropylene ) Honeycomb. (Density: 80-120kg/m³)
Composite Method	Thermoplastic Composite.
Thickness	5.0-150mm.
Length	≤12000mm.
Width	≤2800mm.

Structural Diagram

Thermoplastic composite polypropylene honeycomb panels offer a simple structure and superior performance. It is a typical sandwich structure without any internal added materials.

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Processing Principle

The honeycomb core is fed into the composite area via conveyor rollers. Continuous CFRT-reinforced skins are simultaneously introduced onto the upper and lower surfaces. After being softened by preheating rollers, they are continuously pressed together by a pair of hot pressing rollers (adjustable temperature and pressure). The high temperature of the hot rollers melts the skin resin, while the pressure bonds the skin to the honeycomb core. The core is then cooled and shaped by cooling rollers, achieving continuous composite.

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Common Performance parameters of CFRT sheets

Resin Type	Thermoplastic Polypropylene
Reinforcement Fiber	Continuous Glass Fiber
Using Temperature	≤100°C
Fiber Content	60-75%
Density	1.54-1.63 g/cm³
Thickness (mm)	0.7-2.0 mm or customized
Unidirectional Tape Layers	2-9
Laminating Film (Optional)	Polyester Film (Matte/Glossy/Patterned)

Common Surface Treatment

The surface of thermoplastic composite honeycomb panels can be treated by various methods such as film lamination, embossing, spraying, etc. to improve their application performance and decorative effect.

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Common Performance Parameters of Polypropylene Honeycomb Core

Cell size(mm)	8	10	12
Density(kg/m³)	80	75	70
Compressive Strength(MPa)	1.66	1.58	1.47
Compressive Modulus(MPa)	45.7	41.2	38.9
Shear Modulus(MPa)	0.50	0.45	0.40
Operating Temperature(℃）	-40-80	-40-80	-40-80
Thermal insulation U value	2.2	2.2	2.2

Application of Thermoplastic Composite Honeycomb Panels

Thermoplastic composite honeycomb panels are widely used in many applications that require high strength and light weight. Such as:

• Box Truck Bodies: Dry van trucks, dry cargo trailers.
• RV Bodies: Caravan floors, small travel trailer bodies, teardrop RV bodies, etc.
• Public Transportation: Bus, subway, high-speed rail floors.
• Marine: Decks of yachts and boats.
• Mobile Buildings: Portable toilets, modular houses, etc.
• Sporting Goods: Pickle paddles, basketball backboards, table tennis and billiard tables, etc.
• Outdoor Facilities: Fences, road partitions, scaffolding, mobile stages, fishing platforms, swimming surrounding floors, etc.

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Our Customized Services

TOPOLOGROUP relies on advanced thermoplastic composite material technology to make the production of polypropylene honeycomb composite panels simpler and more efficient, improve the utilization rate of raw materials and shorten production time.

• Professional thermoplastic material experts customize reliable solutions for each user’s project.
• All raw materials are tested through multiple processes to meet production standards.
• Unique top-level automated thermoplastic composite production equipment, with a daily output of thousands of square meters.

Tell us about your application requirements and learn more about thermoplastic composite honeycomb panels.