Description
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.
Uses Include
- General Purpose Aviation Panels
- Aircraft Interiors
- Interior Design
- Marine Paneling
Technical
Documents
Physical Properties
- Core Thickness: .125″, .250″, .500″
- Ply Thickness: .008″
- Total Thickness (TPT) Tolerance: +/- 15%
- Length/Width Tolerance: +/- 0.50″
- Core Material: 6 PCF Polyurethane Foam
- Skin Material: Carbon Fiber Prepreg Style 282 Prepreg
- Resin Content: 42%
Prepreg Neat Resin Properties
- Specific Gravity: 1.286
- Tg dry: 171°F
- Moisture Absorption: 7%
- CTE: 4.75 x 105/in/in/°F
- Tensile Strength: 7.2 ksi
- Tensile Modulus: 0.42 msi
- Tensile Strain: >9.5%
- Fracture Toughness: 4.50 ksi √in
- Strain Energy Release Rate: 34.5 in-lb/in²
Structural Foam Properties
- Density: 6.0 PCF
- Compressive Strength ǁ to rise: 154 psi @ 75°F
- Compressive Strength⊥ to rise: 139 psi @ 75°F
- Compressive Modulus ǁ to rise: 4275 psi @ 75°F
- Compressive Modulus⊥ to rise: 3437 psi @ 75°F
- Tensile Strength ǁ to rise: 182 psi
- Tensile Strength⊥ to rise: 174 psi
- Tensile Modulus ǁ to rise: 5949 psi
- Tensile Modulus⊥ to rise: 5662 psi
- Shear Strength ǁ to rise: 116 psi
- Shear Strength⊥ to rise: 116 psi
- Shear Modulus ǁ to rise: 4133 psi
- Shear Modulus⊥ to rise: 1457 psi
- Flexural Strength ǁ to rise: 226 psi
- Flexural Strength⊥ to rise: 210 psi
- Flexural Modulus ǁ to rise: 5944 psi
- Flexural Modulus⊥ to rise: 5421 psi
- CTE: ~3.4 x 105/in/in/°F
- Closed Cell Content: 95.6%
- Hardness, Shore-D: 11.1
- Water Absorption: 0.17 lbs/ft²
- Specific Heat @ 25°C: 0.353 BTU/lb-°F
- Heat Combustion: 11706 BTU/lb
- Thermal Conductivity: 0.205 BTU*in/ft²*°F*h
Please note: All data to be used as a guide only; not a specification. The technical information is for the stand alone raw materials, not the constructed panel.
~Weight per ft²
- .125″ 1 Ply: 3.5 oz.
- .250″ 1 Ply: 4.6 oz.
- .500″ 1 Ply: 6.6oz.
- .125″ 2 Ply: 6 oz.
- .250″ 2 Ply: 6.9 oz.
- .500″ 2 Ply: 8.9 oz.
Resources
Tips
- 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
Carbon Fiber 1 Ply Foam Core Layup Diagram
Carbon Fiber 2 Ply Foam Core Layup Diagram
Other Resources
- 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.
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.
- 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″*
*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.
- CNC Machining
- Cutting
- Edge Closeouts
- Rebate Edges
- Hard Fix Points
- Fixtures
- Counter Boring
- Bonding
- Joining
- Assembly
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