Carbon Fiber/Foam Sandwich Panels

ACP’s Carbon Fiber/Foam Sandwich Panels are ideal panels for a wide range of applications requiring flat, lightweight and rigid specifications. They are manufactured by ‘sandwiching’ a structural foam core between layers of self-adhesive carbon fiber prepreg. Our sandwich panels are cured with high temperature and under pressure resulting in fully consolidated carbon fiber skins that are completely bonded to the foam core. The resulting constructed panel offers a high strength-to-weight ratio and is ideal for applications where maximum stiffness and crush resistance are essential.

Using carbon fiber prepreg for the outer layers creates structural skins that offer high strength-to-weight ratios, thermal and electrical conductivity, high tensile strength, low density, low weight, low thermal expansion and excellent fatigue resistance.

Manufactured with lightweight, high density structural foam, our foam core sandwich panels demonstrate the light weight, high strength and stiffness properties desired in a foam core panel and are lighter than balsa core panels. By using structural foam, these panels feature higher compressive strength and crushing resistance than panels manufactured with a non-structural foam core. They remain a more economical option and are ideal for applications that require low water absorption and good sound and thermal insulation.

• General Purpose Aviation Panels
• Aircraft Interiors
• Interior Design
• Marine Paneling

• If delamination occurs skins may be re-bonded using any structural adhesive, such as slow set cyanoacrylate (CA) glue or 5 minute epoxy adhesive.
• Sandwich panels can be cut with a cut off wheel or a Tungsten Carbide Saber Saw. Do not cut with a band saw.

• Layup Diagrams

• For specialized panel inserts, fasteners and latches contact The Young Engineers. As an industry-leading designer and manufacturer of hardware, their primary focus is on fasteners for honeycomb panels and composite materials.

As a leading manufacturer of composite structures you can rely on us to provide rapid, cost-effective and high-quality solutions to meet and exceed your project requirements.

Our design and manufacturing team can work with you to fabricate custom sandwich panels. Options include:

• Fiber Selection: Carbon Fiber, Fiberglass, Kevlar®, Other
• Skin Thickness
• Core Selection: Honeycomb (aluminum, plastic, Nomex) and Foam (polyurethane, PVC, ABS & others)
• Core Thickness
• Layup/Construction
• Surface Finish
• Sizes up to 60" x 120"*

We can tailor our stock products to meet your needs by offering the following services:

• CNC Machining
• Cutting
• Edge Closeouts
• Rebate Edges
• Hard Fix Points
• Fixtures
• Counter Boring
• Bonding
• Joining
• Assembly

Contact us today to discuss your requirements.
Already know what your looking for?