Description
ACP Composites AL-X® Aluminum Honeycomb Sandwich Panels are built to withstand the Earth’s atmosphere where unmanned satellites desire to orbit and ensure mission success goals. Constructed of materials with flight heritage and processed with precision. These sandwich panels are widely used in a variety of satellite designs to serve structural functions, shielding, and protection. These panels can be customized to support various resist launch loads and provide attachment points for subsystems.
Manufactured with aerospace grade HexWeb® CR III Aluminum Honeycomb Core, these sandwich panels features excellent corrosion resistance, high strength and rigidity to weight ratio, and high fatigue resistance. The HexWeb® CR III coating offers superior protection for aluminum honeycomb exposed to corrosive environments. It offers a clear protective film that interacts with the aluminum surface forming a stable, tightly adherent bond. The coating is primarily an organometallic polymer type that differs from the normal conversion-type corrosion protective coatings.
The face sheet, or skin of the panel is an Carbon Fiber CFRP bonded to the Aluminum Honeycomb Core with low outgassing, aerospace grade film adhesive. Carbon fiber face sheets are favored when weight reduction is critical, as they offer a higher strength-to-weight ratio than aluminum. They also provide superior stiffness and corrosion resistance, which can be advantageous in specific scenarios. However, for applications prioritizing thermal management, radiation shielding, cost, or ease of fabrication, aluminum often comes out ahead.
If you have a specific panel design or mission profile in mind, reach out and we can discuss you requirements!
5052 and 5056 alloys available.
Post-processing options to include:
- Potted Inserts
- Edge Closeouts
- 3-axis CNC Machining
- Core only machining
- Multi-layer insulation (MLI)
- Doubler Application
- Cleco or Rivnut Assembly
- MIL-Spec Industry Standard Surface Finishes
- Custom packaging
- Customer-owned materials accepted
Feature Benefits
- Compliant with NASA outgassing TVL % & CVCM % exposure requirements
- Custom core thicknesses, cell diameters, and densities available
- High-volume processing capabilities
- Customer-owned materials accepted
- Co-curing capability
- 60” x 120” max footprint processing
- Core splicing capability
Technical
Physical Properties
- Core Thickness: .460″, .960″
- Face Sheet Thickness: .020″
- Total Thickness (TPT): .500″, 1.00″
- Width: +/-0.50″
- Core Material: 5052, 5056 HexWeb® CR III Aluminum Honeycomb
- Skin Material: Carbon Fiber CFRP, Standard Modulus, Woven 2×2 3K Twill
Technical Properties
Please note: All data to be used as a guide only; not a specification.
Customize
Need something different? We’ve got you covered.
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.
We MAKE it.
Our design and manufacturing team can work with you to fabricate custom rods.
- Face sheet Selection: Carbon Fiber, Fiberglass, Kevlar®, Other
- Skin Thickness
- Core Selection: Honeycomb (aluminum, plastic, Nomex) and Foam (polyurethane, PVC, ABS & others), APEX Carbon Core
- Core Thickness
- Layup/Construction
- Surface Finish
- Sizes up to 60″ x 120″*
*ACP has a maximum work envelope of 60″ x 120″. Available options are contingent on tooling and material availability. KEVLAR® is a registered trademark of E.I. du Pont de Nemours and Company and is used with permission.
We CUSTOMIZE it.
- Potted Inserts
- Edge Closeouts
- 3-axis CNC Machining
- Core only machining
- Multi-layer insulation (MLI)
- Doubler Application
- Cleco or Rivnut Assembly
- MIL-Spec Industry Standard Surface Finishes
- Custom packaging
- Customer-owned materials accepted
Discuss a Custom Panel
Have an idea what you’re looking for but need to discuss your requirements in detail?
CONTACT US TODAY!
Shipping
Due to size restrictions, 48″ x 96″ sizes requires custom palletized packaging and can only ship via LTL Freight. A $85.00 handling fee will apply and will automatically be added to the order. Final shipping charges will not be available at the time of ordering. A quote can be requested or shipping charges can be automatically billed at the time of shipment.
FAQ's
What are the benefits of aluminum honeycomb panels?
Key advantages include lightweight construction, high stiffness, corrosion resistance, thermal/acoustic insulation, and recyclability.
How strong are aluminum honeycomb panels?
They provide excellent compressive and shear strength, depending on core density, cell size, and face sheet thickness.
Are aluminum honeycomb panels fire-resistant?
Aluminum is non-combustible, but fire ratings depend on adhesives or coatings used; often rated for low flame spread in specific configurations.
Can aluminum honeycomb panels be customized?
Yes, customization includes panel size, thickness, core density, cell size, and surface finishes and more. Contact us to discuss it.
How do you cut or install aluminum honeycomb panels?
Cut using CNC machines, waterjets, or saws; installed with mechanical fasteners, adhesives, or mounting systems, often requiring edge sealing.
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