Custom Honeycomb Core Panels

When designing and innovating, sometimes basic materials in limited dimensions can be more trouble than they’re worth. That’s why RhinoKore offers custom honeycomb panels and core solutions. Beyond our standard sheets, panels, and thicknesses, we have the capability to produce customized products based on customer specifications.


Customization Options

Our composite panels are an ideal construction material. Superior strength to weight ratios, rot resistance, high compression and shear strength, and insulation values offer clear value for many applications.

RhinoKore operates out of a 90,000 sq. ft. manufacturing facility and has the ability to design and build custom panels to suit your application. Speed up your manufacturing cycle and cut out the hassle by letting us determine the optimal specifications, producing repeatable and accurate cuts. With custom manufacturing, we can meet your specifications with:

  • Chamfered corners
  • Dimensional panels (not flat)
  • Scoring and Matting
  • Panel joining solutions
  • Skinning/facing options
  • Extra large panels
  • Custom thicknesses
  • Fastening solutions
  • CNC services

Facing Materials

Our RhinoKore honeycomb core can be bonded to a wide variety of substrate materials ranging from thermoset and thermoplastic composite skins to metal, wood, or even concrete, forming a lightweight yet stiff and strong sandwich panel that also provides good thermal and acoustical insulation as well as impact strength (damage tolerance).


Aluminum on honeycomb foam core
Aluminum
G10 Fiberglass on honeycomb foam core
G10 Fiberglass
Carpet on honeycomb foam core
Carpet
Linoleum on honeycomb foam core
Linoleum
Fiberglass on honeycomb foam core
Fiberglass
Lauan plywood on honeycomb foam core
Lauan
Impact Flooring on honeycomb foam core
Impact Flooring
RV Panel on honeycomb foam core
RV Panel
MDF-Structural Insulated Panel on honeycomb foam core
MDF-Structural Insulated Panel

​Choose a Core Material to Meet Your Needs

Choose from our lightweight RhinoKore phenolic kraft paper honeycomb core (P100) or our versatile RhinoKore synthetic honeycomb core (S150). Both can be ordered with or without foam injection and facing. Our honeycomb core can be bonded with a wide variety of substrate materials including (but not limited to) thermoset and thermoplastic composite skins, metal, wood, concrete, and fiberglass. The addition of facing can enhance thermal and acoustical insulation as well as impact strength.

P100 provides excellent stiffness while still having water resistant benefits. S150’s synthetic cores are comprised of polypropylene, which gives it more flexibility and will not support the growth of mildew or fungi. Contact us today and let us know what you have in mind. We have customers using our honeycomb cores for Marine Countertops & Cabinetry, RV floors, and walls, Public Bus Transportation, Skis, Boat Paddles, Commercial and Residential Construction, and more.

Frequently Asked Questions

Honeycomb panels are available up to 4’ x 8’. Thicknesses range from ¼” to 12”

RhinoKore S150 Synthetic Foam Injected Honeycomb Panels weigh 14.2 oz./ sq. ft.

RhinoKore P100 Phenolic Kraft Foam Injected Honeycomb Panels weigh 10.2 oz./ sq. ft.

Note: Based on 12 in. x 12 in. x 1 in. sample

Yes, both honeycomb panels can be ordered without foam injection

RhinoKore S150 Synthetic Foam Injected Honeycomb Panels at 1 in. thick has an R 3.19 rating

RhinoKore P100 Phenolic Kraft Foam Injected Honeycomb Panels at 1 in. thick has an R 3.15 rating

Most traditional building products from thermoset and thermoplastic composite skins to metal, wood, or even concrete can effectively adhere to the surface of the RhinoKore honeycomb panels

RhinoKore foam injected honeycomb panels are less than half the weight of plywood and are not susceptible to rot.

RhinoKore S150 Synthetic Foam Injected Honeycomb Panels at 1`` thick has a 191 psi shear strength rating.

RhinoKore P100 Phenolic Kraft Foam Injected Honeycomb Panels at 1`` thick has a 156 psi shear strength rating.

RhinoKore S150 Synthetic Foam Injected Honeycomb Panels at 1`` thick has a 404 psi compressive strength rating.

RhinoKore P100 Phenolic Kraft Foam Injected Honeycomb Panels at 1`` thick has a 437 psi compressive strength rating.

RhinoKore S150 Synthetic Foam Injected Honeycomb Panels at 1`` thick has a 158.8 psi flexural strength rating at 5% strain.

RhinoKore P100 Phenolic Kraft Foam Injected Honeycomb Panels at 1`` thick has a 100.4 psi flexural strength rating at 5% strain.

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