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Description
This premium non-woven composite core material is engineered as a lightweight, stable and cost-effective core for advanced composite laminates. Designed to sit between reinforcing skins such as glass or carbon fibre, it delivers excellent stiffness-to-weight performance while helping to control resin usage and optimise overall laminate weight.
Ideal for marine, industrial, transport and general composite fabrication, this core material is supplied in convenient sheet form with a fixed width of 1000 mm and a choice of sheet lengths and thicknesses. It is well suited to hulls, decks, panels, covers, fairings and structural or semi-structural components where reduced weight, improved fatigue performance and consistent quality are required.
Product Features
- Non-woven composite core material designed for use between reinforcing skins in sandwich structures.
- Available in standard sheet width of 1000 mm for easy handling and straightforward nesting on typical mould sizes.
- Choice of sheet lengths including 1000, 2000, 3000, 4000 and 5000 mm, with additional lengths available to suit larger or continuous lay-up areas.
- Offered in three practical thickness options: 1.4 mm, 3 mm and 5 mm to meet varying stiffness, weight and laminate design requirements.
- Lightweight construction enables weight savings in marine and industrial components without compromising structural integrity.
- Non-woven structure promotes even resin distribution and good conformability over gentle curves and profiles.
- Supplied as flat sheets for consistent thickness control, simplified cutting and efficient storage.
Key Features and Benefits
- Helps reduce overall laminate weight, supporting fuel efficiency and easier handling of finished parts.
- Provides a cost-effective alternative to heavier or more complex core systems, helping to control project material costs.
- Consistent sheet thickness and density contribute to uniform mechanical performance across the finished component.
- Easy to cut, shape and position, allowing efficient fabrication and reduced labour time during lay-up.
- Improves stiffness-to-weight ratio of laminates, enabling thinner skins or reduced glass content in suitable designs.
- Compatible with common composite manufacturing methods, supporting both prototype and production-scale builds.
Specifications
| Specification | Detail |
|---|---|
| Product type | Non-woven composite core material in flat sheet form |
| Sheet width | 1000 mm (nominal) |
| Sheet lengths available | 1000, 2000, 3000, 4000, 5000 mm (plus additional length options subject to selection) |
| Thickness options | 1.4 mm, 3 mm, 5 mm |
| Typical applications | Marine panels, decks and hull areas; industrial panels and covers; lightweight structural elements |
| Format | Rigid, lightweight non-woven core for use within composite sandwich constructions |
Applications and Ideal Uses
This non-woven composite core material is suitable for a wide range of lightweight structural and semi-structural panels in marine, industrial and transport environments.
- Marine hulls, decks, bulkheads and interior panels where weight saving is important.
- Industrial equipment panels, machine guards and access covers needing stiffness with reduced mass.
- Lightweight structural panels and cladding in transport, trailers and specialist vehicles.
- General composite laminates, fairings, enclosures and housings requiring dimensional stability and controlled resin usage.
- Prototype and production composite components where repeatable core properties are needed.
Frequently Asked Questions
Which thickness of composite core material should I choose for my application?
The choice of thickness depends on the stiffness and weight targets for your laminate. The 1.4 mm option is ideal where minimal weight and a low profile are essential, such as thin panels or skins. The 3 mm and 5 mm cores provide progressively higher stiffness and can help reduce the amount of reinforcement required in suitable designs. It is recommended to consult your laminate design specifications or carry out testing to confirm the best option for your application.
Can this non-woven core material be cut and shaped easily?
Yes, the material can typically be cut using common workshop tools such as sharp knives, fine-toothed saws or shears, depending on thickness and your specific workshop setup. Sheets can be trimmed to size and shaped to fit moulds or panel outlines. Care should be taken to maintain clean edges and avoid excessive compression of the core during cutting.
Is this core material suitable for use with standard composite resins and lay-up methods?
The core is intended for use within composite laminates and is generally compatible with widely used resin systems and lay-up methods, including hand lay-up and other common processes. As with any core material, it is advisable to test compatibility with your chosen resin, curing conditions and processing method before full-scale production, particularly for critical or highly loaded components.