Core material processing

Home Services Core material processing

From sheets to kits: Precision core material processing for every industry

Sky Composites delivers industry-leading core material processing and kitting services through its global network, including Marex Composites, a trusted provider specializing in core material customization. High-end reliable products, adequate and stable stocks, advanced and efficient processing equipment, experienced management team, as well as internationally dependable logistics networks have laid an important foundation for Sky Composites’ global services of structure core materials.

With facilities in China, the USA, and Hungary, we transform premium materials such as PVC foam, balsa wood, PET, and PMI into customized kits ready for use in marine, aerospace, wind energy, and transportation industries.

Why choose Sky Composites for core material processing & kitting?

Global expertise

Over 20 years of experience with a network spanning Maricell PVC foam (Italy), Cobalsa balsa wood (Ecuador), and Marex’s kitting facility (USA).

Comprehensive customization

Full range of finishes, including scrim, score, perforated, slit, and more, tailored to your specifications.

High-quality standards

Advanced equipment and expert teams ensure precision, consistency, and quick turnaround.

Reliable supply chain

Stable stock and dependable logistics guarantee on-time delivery for projects of any size.

Core material finishing services

Finishing involves the precise machining of structural core materials to enhance performance and adaptability. At SKY, we offer a variety of cuts, grooves, and perforations in different patterns, each tailored to meet specific requirements for formability, resin flow, and component performance.

Our proven designs for grooves and perforations not only improve performance but also reduce costs. Finishes optimized for resin flow eliminate the need for additional flow media and reduce the number of resin inlets required. This leads to faster processing, better wet-out of fibers, and significant material savings.

Plain

Infusion cut

Double slit

Plain perforated

Single slit

Grid score

Benefits of core material finishing

Improved formability: Enables cores to adapt seamlessly to complex mould surfaces.
Weight reduction: Optimized grooves and perforations minimize weight without compromising strength.
Enhanced resin flow: Facilitates faster, more secure resin distribution during vacuum infusion.
Effective air evacuation: Ensures complete air removal for superior bonding in vacuum processes.
Superior surface finish: Results in smoother, higher-quality final parts.

Tailored kitting solutions

SKY’s kitting services eliminate the inefficiencies and inconsistencies of on-site material tailoring by providing pre-cut core kits customized to your mould and manufacturing process. From simple panels to intricate 3D shapes crafted with CNC routing, each piece is labeled, numbered, and optimized for weight, cost, and quality.

Pre-cut kits streamline production by reducing labor, waste, and cutting time, while improving assembly speed, surface quality, and consistency. With simplified logistics and detailed assembly drawings, SKY’s tailored solutions make your manufacturing process faster, more efficient, and reliable.

Kitting services include:

Custom shapes and sizes for specific moulds.
Labeled and sequenced kits for easy assembly.
Samples to test material suitability.

About Marex: Our customized core material solution provider

Marex Composites, established in 2016, is part of our global network specializing in distributing and finishing structural core materials. We customize Maricell PVC foam and balsa wood with finishes like scrim, score, perforation, and grooves, delivering lightweight, tailored solutions with fast, reliable lead times.