1. Core Advantages - How a Sandwich Panel Actually Carries Load
The top and bottom skins carry tension and compression. Thin carbon face sheets do the bending work - stiff and strong in-plane.
The foam core keeps the skins apart and carries shear. A low-density PVC/PU core holds the skins at distance (that's where bending stiffness lives) while weighing almost nothing. This is why a 10 mm sandwich panel out-stiffens a solid plate several times its weight.
Edges and point loads need reinforcement. Core alone can't carry a bolt. We close out edges and pad mounting zones - that's the difference between a panel that survives assembly and one that crushes at the first screw.
The payoff: flat, stiff, buoyant and corrosion-free - the default choice for weight-driven structures from drone airframes to marine interiors. A 6 mm panel class runs ~2.7 kg/m² while keeping bending stiffness.
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2. Parameter Table (Typical Values)
Foam core density grades (PVC structural foam):
表格
| Core grade | Density (kg/m³) | Shear strength (MPa) | Compression (MPa) | Typical use |
|---|---|---|---|---|
| P48 class | ~48 | ~1.0 | ~1.3 | Ultra-light, non-critical |
| P80 | ~80 | ~1.5 | ~2.0 | Drone structures, general |
| P100 | ~100 | ~2.0 | ~2.8 | Marine, load paths |
| P150–P250 | 150–250 | up to ~3.0 | up to ~4.5 | High-load, impact zones |
Panel build:
表格
| Parameter | Typical value | Note |
|---|---|---|
| Carbon skin thickness | 0.6 – 5.0 mm per face | 3K twill or UD |
| Core thickness | 3 – 60 mm | PVC / PU foam |
| Panel size | Standard sheets or custom | |
| Weight | ~2.7 kg/m² at 6 mm class | Skin + core dependent |
| Service temperature | 70 – 90 °C | PVC foam class |
| Water absorption | 0.12 – 0.25% | Marine suitable |
Typical industry values; locked from your load case, measured sample and batch reports.
3. Customization - Three Layers You Configure
Face sheets: carbon weave, skin thickness, one-sided or two-sided glossy.
Core: density grade and thickness chosen from your load case - lightest where it's just a panel, denser where loads land.
Edges & inserts: edge close-outs, plywood/inserts at mounting points, CNC cut to your outline.
Send the drawing or load case; we recommend the build and quote.
4. Company Advantages
Sandwich quality is decided at the skin-core bond.
Bond control. Skin-to-core adhesion processed as a documented step - the failure everyone sees first is debonding, and it starts in the layup.
Flat, consistent panels. Core thickness and skin layup controlled run to run; reorders match the approved sample.
One factory. Core selection, skin layup and CNC finishing in-house.
Our boundary. We build the panel to your spec. Structural load calculations and core-joint design belong to your engineer - we recommend, they certify.
5. FAQ
Q: How do I choose the core density? By load case: lightest grades for non-critical panels, denser PVC where shear and compression matter. Tell us the loads; we recommend the grade.
Q: Can I drill and bolt directly into the panel? No - foam core crushes under point loads. Mounting zones need inserts or plywood pads; we can build them in.
Q: How is impact damage handled? Sandwich panels dent locally rather than break; denser core grades improve impact resistance. Edge zones take the first hit - close them out.
Q: Marine and UV exposure OK? PVC foam absorbs minimal water; the carbon face and gel finish need appropriate coating for long-term UV. Specify the environment.
Q: What panel thicknesses can you make? Core 3–60 mm, skins per face - tell us the stiffness target.
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