Structural honeycomb built for real-world challenges
Build with confidence using our Carbon-Core lightweight plastic honeycomb core materials. Engineered for durability and resilience, these cores deliver exceptional strength and sound-damping capabilities to handle real-world challenges, whether on the water or in tough industrial environments. Trust Carbon-Core for lightweight, tough, and reliable performance.
Why choose structural honeycomb?
Durable
Certain cores are designed to be stiff, lightweight, quiet, or cost-effective - Carbon-Core simultaneously excels in all three of these areas, incorporating durable polypropylene and thermo-fused scrim for enhanced impact absorption.
Sound and vibration damping
Polypropylene honeycomb offers excellent sound dampening and vibrational reduction due to its viscoelasticity and unique cell structure, outperforming traditional lightweight sheets.
Lightweight, perfect for marine applications
Carbon-Core polypropylene honeycomb, with bonded polyester scrims and a resin-limiting barrier film, is a durable, US Coast Guard-approved flotation material for small boats when laminated.
Engineered to your exact needs
Carbon-Core Honeycomb sheets are designed to meet precise application needs by adjusting key specifications, including:
- Thermoplastic properties
- Cell size and wall thickness
- Core and facing thickness
These adjustments allow for customized performance characteristics, such as weight, load absorption, rebound rate, and the ideal balance of flexibility or stiffness for your application.
Rot-proof & corrosion-resistant core material
Unlike PVC, SAN foams, plywood, or balsa, Carbon-Core plastic honeycomb doesn’t rot or weaken when exposed to water, chemicals, or solvents. Encapsulated in laminate with non-aqueous resin, it forms a water-resistant seal, even if punctured. Its exceptional durability makes it a reliable choice for industries where corrosion resistance is critical, such as automotive, oil platforms, chemical containment, and industrial tanks.
100% recyclable for sustainable solutions
Carbon-Core’s 100% recyclable honeycomb panels are ideal for eco-conscious applications, especially in the automotive industry. With customizable facings and thermoformable properties, they reduce production costs while offering a sustainable, high-performance material for large-scale manufacturing.
Plastic Honeycomb Sheet scoring and converting by Carbon-Core Corp.
Ready to build stronger solutions together?
Partner with Sky Composites to bring innovative, high-performance materials to your industry. Let’s shape the future, one composite at a time.