Engineered

Polypropylene Core

PP
Honeycomb

Plascore PP Honeycomb

Light, Strong, Tough, Cost-Effective

Ref. -00

Ref. -20

Ref. -01 / -10

Plascore PP Honeycomb is a tough, lightweight and
ductile polypropylene material that provides efficient
and optimum mechanical performance in composite
sandwich structures.
PP Honeycomb is an excellent alternative to traditional
core materials such as plywood, balsa and foam used in
the manufacturing of consumer and industrial products.
Available in a wide range of sheet sizes and facings,
PP Honeycomb is engineered for ease of use in many
mainstream manufacturing processes, is readily
available and can be modified to meet specific
requirements for strength and stiffness.
Plascore PP Honeycomb provides properties used
in many composite sandwich structures that require
core shear and compression along with adhesion
performance. The unique cell structure, the use of a high
impact copolymer PP and unique material processing
contribute to its attractive performance levels.

Ref. -30

Multi-axial structure provides isotropic

performance
Engineered raw materials for higher
performance
Uniform and uninterrupted cell structure
throughout entire sheet
Integral and thermally fused facings for
optimal adhesion
Non woven surface is compatible with most
Epoxy, Polyester, Vinyl Ester, Urethane and
Methacrylate Resin systems
Minimizes laminating resin while fully
wetting out
Continues to absorb energy, even after
ultimate yield
Recyclable

Value Added Configurations

To Meet Your Requirements

Open Cell
PP Honeycomb Ref. -00

Description

Availability

Uses

PP Honeycomb with Veil

or Veil with Film Ref. -01/-10

Infusion Grade
PP Honeycomb Ref. -20

PP Honeycomb with Reinforced

PP Facings Ref. -30

PP Honeycomb Core:
Open cell structure
No facings

PP Honeycomb Core:
Faced with a lightweight
non-woven polyester (-01)
Faced with a lightweight
non-woven polyester with an
internal PP film barrier (-10)

PP Honeycomb Core:
Faced with a composite
surfacing material
No flow medium incorporated

PP Honeycomb Core:
Faced with Reinforced-PP
stress skins
Reinforcement types:
- Chopped - Natural fiber
- Woven - Uni-directional

glass

All densities and sheet sizes

All densities and sheet sizes:

Options of unscored or
scored to a 1" x 1" or 2" x 2"
grid pattern
Scored material is limited to
no larger than 96" dimensions

Sheet sizes:
All densities. Up to 48" x 96"
standard
Pre-punched pass through
holes available on sheet
sizes up to 24" x 48"

Sheet sizes:
Up to 72" wide x 144" length
standard
Facing material may limit
some sizes
Special widths and lengths
available upon request

Core material for thermoplastic molding of sandwich

structures
Air and fluid flow medium

Core material in thermoset

bonding of sandwich structures:
Open Molding
Platen Press
Wet Vacuum Bagging
processes

Core material in closed molding:

Lite RTM
Closed Cavity Bag Molding
Vacuum Infusion

Preconsolidated lightweight
boards to replace plywood or
other thermoset composite
sandwich panels

PP Honeycomb Core Mechanical Properties

CORE

CELL SIZE
(in)

(mm)

DENSITY
TYPICAL
lb/ft3 kg/m3

MINIMUM
lb/ft3 kg/m3

FLATWISE
TENSILE1
STRENGTH
psi
MPa

BARE COMPRESSION2
STRENGTH
TYPICAL
MINIMUM
psi
MPa psi
MPa

MODULUS
TYPICAL
MINIMUM
ksi
MPa
ksi MPa

PLATE SHEAR3
STRENGTH
TYPICAL
MINIMUM
psi MPa
psi
MPa

MODULUS
TYPICAL
MINIMUM
ksi MPa ksi
MPa

PP1-5.0-N1-8 0.315

5 80.0 4.75 75.0 130 0.89 275 1.89 255 1.55 11.5 79.2 9.5 65.4 85 0.58 75 0.52 2.2 15.2 1.7 11.7

PP1-4.0-N1-10 0.395

10

4 64.0 3.8 60.0 120 0.83 180 1.24 140 0.96 10.5 72.3 8.5 58.5 60 0.41 55 0.38 2.0 13.8 1.5 10.3

The data provided is based on the testing

of -01 (veil only) version of each core type.

1
Flatwise Tensile
Tested per ASTM C 297

2
Bare Compression
Tested per ASTM C 365

3
Plate Shear
Tested per ASTM C 273

RESIN-FILLED GLASS
RESIN INLET

Ideal for your Process

RESIN

VACUUM BAG
AIR

AIR

SEALING
TAPE

SEALING
TAPE

Easily Bonded, Molded and Fabricated

FILLET
MATERIAL

FILLET
MATERIAL

HOT PLATTEN

Open Molding

Compression
Molding MOLDING
COMPRESSION

LAMINATE FACING

Resin

HOT PLATTEN
CORE
HOT PLATTEN

Non-Woven

ADHESIVE

INFRARED HEATING

Hat Section

PRESSURE
MALE
MOLD

LAMINATE FACING
LAMINATE FACING

LAMINATE FACING

CORE

ADHESIVE

CORE

ADHESIVE

Resin

Non-Woven

Resin

Non-Woven

HOT PLATTEN

Hat Section

RTM

Hat Section

AUTOMATIC TRANSFER

LAMINATE FACING

LAMINATE FACING
LAMINATE FACING

RESIN-FILLED GLASS
RESIN INLET
CORE

RTM
RTM

Resin

Non-Woven

RESIN
ADHESIVE

VACUUM BAG
AIR

Hat Section

AIR

SEALING
TAPE

SEALING
TAPE

LAMINATE
FACING GLASS
RESIN-FILLED

Adhesive resin can be

applied in a variety of
RTM from spray, rolled,
methods
brushed and troweled
COMPRESSION
RESIN-FILLED
on. TakingMOLDING
care
toGLASS
set the
honeycomb core into the
resin with hand pressure
will ensure the resin comes
COMPRESSION MOLDINGin full contact with the non woven bonding surface of the
COMPRESSION MOLDING
PP Honeycomb. The lightweight non woven will not take
much resin to wet out (400 g/m2 or .08 psf), but getting good
coverage and penetration through some process pressure
is important. When applying the resin straight to the core
BUOYANCY
COMPRESSION
surface
orMOLDING
through a wet, glass laminate schedule, rolling
the surface with a hard roller will also ensure good wet out
and contact between the core and laminate. For complex
shapes, scoring the PP Honeycomb will allow it to drape
BUOYANCY
and contour to the shape desired and thus providing good
BUOYANCY
contact to the core-laminate bond line.

RESIN INLET
RESIN INLET
VACUUM BAG

RESIN

RESIN-FILLED GLASS
FILLET
MATERIAL

FILLET
MATERIAL
FILLET
MATERIAL

FILLET
MATERIAL

RESIN

VACUUM BAG
AIR
SEALING AIR
TAPE
SEALING
TAPE

PP HONEYCOMB CORE

AIR

AIR SEALING
TAPE
SEALING
TAPE

FILLET
MATERIAL
FILLET
MATERIAL
RESIN INLET

RESIN

INFRARED HEATING
VACUUM BAG
AIR

PRESSURE

AIR

PP HONEYCOMB CORE

SEALING
TAPE

FILLET
MATERIAL

FILLET
AUTOMATIC TRANSFER
MATERIAL

INFRARED HEATING

PRESSURE

INFRARED HEATING

PRESSURE
MALE
MOLD
MALE
MOLD

PP HONEYCOMB CORE
PP HONEYCOMB CORE

MALE
MOLD

SEALING
TAPE

AUTOMATIC TRANSFER
AUTOMATIC TRANSFER

INFRARED HEATING

PRESSURE

18.0 lbs (F )

MALE
MOLD

PP HONEYCOMB CORE
5pcf PP HONEYCOMB

AUTOMATIC TRANSFER

18.0 lbs (F )
5pcf PP HONEYCOMB

18.0 lbs (F )

Vacuum Bagging
1"T 24" 24" = .33 ft3, est. 6 lb/ft3 total
.333 6 = 2.0 lbs of PP HONEYCOMB
2.0 lbs 10 (Bouyancy Factor) = 20 lbs

5pcf PP HONEYCOMB

Traditional wet vacuum bagging requires a standard PP

BUOYANCY
film barrier under the non woven of the PP Honeycomb.
This will minimize the amount of resin penetration into the
cells of the honeycomb while under vacuum pressure.
Though not 100% non porous, this film barrier provides
enough of a barrier that 90% of the resin will stay at the
bond line and in the reinforcement during the process. The
amount of penetration will depend on resin viscosity, gel
time, process temperature and ultimate vacuum pressure.

1"T 24" 24" = .33 ft3, est. 6 lb/ft3 total

.333 6 = 2.0 lbs of PP HONEYCOMB
1"T 24" 24" = .33 ft3, est. 6 lb/ft3 total
2.0 lbs 10 (Bouyancy Factor) = 20 lbs
.333 6 = 2.0 lbs of PP HONEYCOMB
2.0 lbs 10 (Bouyancy Factor) =5pcf
20 lbs
PP HONEYCOMB

18.0 lbs (F )

1"T 24" 24" = .33 ft3, est. 6 lb/ft3 total

.333 6 = 2.0 lbs of PP HONEYCOMB
2.0 lbs 10 (Bouyancy Factor) = 20 lbs

PP Honeycomb with a variety of thermoplastic stress skins

can be formed through a combination of conventional
BUOYANCY
thermoforming and compression
molding processes.
Depending on the complexity of the part geometry, part
thickness, Honeycomb density and stress skin type and
amount, the process parameters of time, temperature and
18.0 lbs (F )
pressure will vary. The process
objective is to drive enough
5pcf PP into
HONEYCOMB
temperature
the facing materials such that they are
near their melting point for molding and laminating to the
honeycomb core. As the stress skins heat up, so does
the internal honeycomb core. The amount of heat on the
honeycomb core should only be enough to mold into the
desired shape. Too much heat internally on the honeycomb
core will cause it1"Tto melt
= .33loose
24" 24"and
ft , est. 6its
lb/ftstructure.
total
3

.333 6 = 2.0 lbs of PP HONEYCOMB

2.0 lbs 10 (Bouyancy Factor) = 20 lbs

HOT PLATTEN

LAMINATE FACING

HOT PLATTEN

Resin

Closed Molding

Non-Woven

Cold and Hot Platen Press

CORE

ADHESIVE

LAMINATE FACING

Hat Section
Resin

LAMINATE FACING

ADHESIVE

CORE

Hat Sect

LAMINATE FACING

RTM

HOT PLATTEN

HOT PLATTEN

LAMINATE FACING

Uniform and constant pressure during the adhesive cure cycle

ensures a good bond line. This can be accomplished both in
Cold and Hot Platen press processes.
Choosing which press
RTM
process will be dictated by the resin-adhesive chosen to
laminate the PP Honeycomb to the stress skin material. Resin
out-gassing and thermal expansion need to be accounted
RESIN-FILLED
for during Hot Platen press process to
ensure anGLASS
optimum
bond between the PP Honeycomb
and
the
stress
skin.
RTM
RESIN

LAMINATE FACING

RESIN INLET

HOT PLATTEN

RESIN

Resin

Resin

RESIN-FILLED GLASS

CORE

CORE

Non-Woven
Non-Woven

ADHESIVE

ADHESIVE

Hat Section

Hat Section

LAMINATE FACING

VACUUM BAG

LAMINATE FACING

LAMINATE FACING

AIR

AIR
CORE

SEALING
TAPE

Non-Woven

ADHESIVE

SEALING
TAPE

Hat Section

RTM

LAMINATE FACING

FILLET
MATERIAL

Resin

RESIN INLET

VACUUM BAG
Easily
Fabricated
HOT PLATTEN
RESIN-FILLED GLASS

FILLET
MATERIAL

RESIN INLET

RTM

HOTRESIN
PLATTEN

VACUUM BAG

RESIN INLET

AIR
VACUUM BAG

SEALING
SEALING
TAPE
TAPE

LAMINATE FACING
AIR
LAMINATE FACING
SEALING
TAPE

RESIN-FILLED GLASS

RESIN-FILLED GLASS

RESIN

AIR

AIR

FILLET
MATERIAL

AIR
AIR

SEALING
TAPE

SEALING
ResinTAPE

SEALING
TAPE

Resin

Non-Woven

FILLET
MATERIAL

Lite RTM, Closed Bag or Vacuum Infusion

at
HOT processes
PLATTEN
FILLET
MATERIAL
room temperature can be accomplished with Plascore PP
Honeycomb Infusion Grade. The open cell structure of
the honeycomb is
sealed, thereby allowing
the flow of resin
COMPRESSION
MOLDING
COMPRESSION MOLDING
COMPRESSION MOLDING
during processing to stay at the bond line with no or minimal
penetration into the honeycomb core. Strategically placed
RTM
RTM
throughINFRARED
holes HEATING
allow resin to flow top to bottom. PRESSURE
Plascore
PP Honeycomb Infusion Grade does not have resinMALE
flow
RESIN-FILLED GLASS
RESIN-FILLED GLASS
HONEYCOMB
CORE grade reinforcements,
MOLD
COMPRESSION MOLDING
paths in its surface. PP
Using
infusion
COMPRESSION MOLDING
additional flow medium and infusion grade resins is critical
RTM
to allowing good resin flow through the reinforcements.
RESIN

RESIN INLET

FILLET
CORE
MATERIAL
CORE

FILLET
ADHESIVE
MATERIAL
ADHESIVE

Hat Section
Hat Section

VACUUM BAG
AIR

LAMINATE FACING

AIR

SEALING
LAMINATE FACINGResinTAPE

FILLET
MATERIAL

CORE

FILLET
MATERIAL

LAMINATE FACING

SEALING
TAPE

Non-Woven

FILLET
MATERIAL

ADHESIVE

Hat SectionINFRARED HEATING

PRESSURE

INFRARED HEATING

PRESSURE

MALE
MOLD

PP HONEYCOMB CORE
MALE
MOLD

PP HONEYCOMB CORE

LAMINATE FACING

RESIN

RESIN INLET

SEALING AIR
TAPE
PP HONEYCOMB CORE SEALING
TAPE

AUTOMATIC TRANSFER
RESIN-FILLED GLASS

RESIN

AIR

AIR

PRESSURE

TAPE

PP Honeycomb is easily cut

BUOYANCY
with BUOYANCY
a razor knife, circular
PP HONEYCOMB CORE
saw, band saw, wire saw,
CNC water jet, CNC ultrasonic
knife
and steel rule die
COMPRESSION MOLDING
COMPRESSIONprocesses.
MOLDING
punching
FILLET
MATERIAL
FILLET
MATERIAL

5pcf PP HONEYCOMB

5pcf PP HONEYCOMB

BUOYANCY

INFRARED HEATING

PRESSURE

INFRARED HEATING

PRESSURE
MALE
24" = .33 ft3, est. 6 lb/ft3 total
1"T 24"MOLD
6 = 2.0 lbs of PP HONEYCOMB
.333 MALE
MOLD
2.0 lbs 10 (Bouyancy Factor) = 20 lbs

18.0 lbs (F )
5pcf PP HONEYCOMB

PP HONEYCOMB CORE
3
24" = .33 ftCORE
1"T PP24"HONEYCOMB
, est. 6 lb/ft3 total
.333 6 = 2.0 lbs of PP HONEYCOMB
2.0 lbs 10 (Bouyancy Factor) = 20 lbs

COMPRESSION MOLDING

AUTOMATIC TRANSFER
AUTOMATIC TRANSFER

INFRARED HEATING

18.0 lbs (F )

PP HONEYCOMB CORE

MALE
MOLD

18.0 lbs (F )

FILLET
MATERIAL

BUOYANCY

AIR SEALING

TAPE
INFRARED HEATING
SEALING

18.0 lbs (F )

SEALING
TAPE

FILLET
MATERIAL

AIR

MALE
MOLD

FILLET
MATERIAL
FILLET
MATERIAL
AUTOMATIC TRANSFER

VACUUM BAG

SEALING
TAPE

AUTOMATIC TRANSFER

VACUUM BAG
AIR PRESSURE

INFRARED HEATING

RESIN INLET

AUTOMATIC TRANSFER

RESIN

RESIN INLET
VACUUM BAG

PRESSURE
MALE
24" = .33 ft3, est. 6 lb/ft3 total
1"T 24"MOLD
.333 6 = 2.0 lbs of PP HONEYCOMB
2.0 lbs 10 (Bouyancy Factor) = 20 lbs

5pcf PP HONEYCOMB
AUTOMATIC TRANSFER

BUOYANCY
BUOYANCY

Non-Woven

BUOYANCY

AUTOMATIC TRANSFER

14
16
12
14
10
12
8
10
6
8
4
6
2
4

Key Performance Criteria

Outperforms Other Cores and Laminates

"
Plywood
"
Plywood

FORCE

" PP
Honeycomb
with 3mm
" PP
Luaun
Honeycomb
both sides

MATERIAL

0.5

0.6

0.7

0.8

0.9

BUOYANCY

FORCE

Core Type

Relative
Cost

Relative
Weight

Relative
Deflection

PP Honeycomb

Balsa

1.2

1.25

0.9

5 pcf

Resin

In most applications with moderate loading

and unsupported
spans of 24"
Area = Energy
Absorbed
or greater, PP Honeycomb core can provide a more cost effective solution
than other core materials with higher shear properties. By balancing the
0
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
overall sandwich thickness with
an0.1appropriate
laminate
type
and
amount,
DISPLACEMENT
PP Honeycomb provides enough shear resistance to achieve most design
deflection criteria in these cases. As the shear deflection component of total
deflection is generally a smaller contributor than the laminate's contribution in
Hat Sectioncore solution.
bending, PP Honeycomb becomes an effective

9.5 pcf

Relative
Relative
Relative
Panel Reference Type:
Type
Weight
"T xCore
48" x 48",
.02"T aluminumCost
both sides, simply
supported,Deflection
center load.

FLEXURAL
PP Honeycomb
1

RESPONSE
1

FLEXURAL
Balsa

RESPONSE

5 pcf

Resin

16

both sides

both sides

9.5 pcf

Balsa
9.5 pcfX-PVC

" PP
Honeycomb

" PP
Honeycomb

with 3mm
Luaun
both sides

with 0.5mm
Glass - PP
both sides

Varying the honeycomb cell size,2 density "

and thickness, in combination with
Plywood
BUOYANCY
the porous non woven polyester surfacing veil, one can tune PP Honeycomb
to a specific frequency range for optimum absorption
efficiency. Up to 99%
MATERIAL
sound absorption can be achieved.

BUOYANCY

Unaffected by Moisture
The mechanical properties remain unaffected even after long periods of
exposure to moisture. Some minimal air drying may be required prior to
FLEXURAL RESPONSE
laminating to remove any residual moisture from the surface or cells of
the honeycomb. Always store the material
Balsa in a dry environment.
9.5 pcf

SHEAR STRESS

X-PVC
5 pcf

VALUE RATIO
PERCENT LOSS
ABSORPTION
ABSORPTION
COEFFICIENT
COEFFICIENT

Efficient Sound Absorber

6

1.5
1.0

5 pcf
Relative
Cost

5 pcf

Unaffected by Most Chemicals

Area = Energy Absorbed

Balsa
9.5 pcf
10

PP Honeycomb
5 pcf

Area 10
= Energy Absorbed
20

0.5

10

30

40

% SHEAR STRAIN
20

1.5

30

40

1.0
1.0

SOUND
Relative ABSORPTION
Relative
Relative
PP HoneycombDeflection
Balsa
Cost
Weight
MATERIAL
PLASCORE
PP30-5
(5 pcf)
SOUND ABSORPTION (9.5 pcf)
Ex. Panel "T x 48"PP
withHoneycomb
.02"T aluminum 5skins
pcfboth sides,
PLASCORE
simply supported,
center load PP30-5
PP Honeycomb 5 pcf

0.8
0.5
1.0
0.6
0.8
0.4
0.6
0.2
0.4

Wet Strength Loss

Plascore
Marine
Ex. Panel
"T x 48"
with .02"T aluminum skins both sides,PVC
Balsa
Paper HC
0.2 simply supported,
PP
Plywood
1000
2000
4000
5000
6000Foam
center 3000
load
13%
0%
" T
1
FREQUENCY
(Hz)

20%

1000

2000

3000

FREQUENCY (Hz)

4000

5000

" T

6000

Wet Strength Loss

40%

After Exposure
to 120F, Condesing Humidity
56%
58% for 7 Days
59%

60%

Plascore
PP

Marine
Plywood

Balsa

Paper HC

PVC
Foam
13%

0%
20%
40%

56%
60%

59%

58%

CORE COMPARISON

Flammability

Balsa

Foam

Aluminum

Balsa

DENSITY
lb/ft +

Foam

Aluminum

PP Honeycomb

SOUND ABSORPTION
PLASCORE PP30-5

DENS
lb/f
DENS
lb/f

PP Honeycomb
Balsa
MATERIAL
After
Exposure to 120F, Condesing Humidity for 7 Days
(5 pcf)
(9.5 pcf)

oneycomb

PTION COEFFICIENTSHEAR STRESS

% SHEAR STRAIN

0.6

0.2

60%

0.9

40
PP Honeycomb is unaffected by most acids, bases20 and to 30
Flammability:
When tested to UL94 Horizontal Burn, the
X-PVC
% SHEAR
STRAIN
a lesser degree, organic substances and solvents.
Certain
material
is flammable. When
5 pcf
+ used in conjunction with a
chemical concentrations and temperature variables may
variety of stress skins, Flammability ratings to UL 94,
SOUND ABSORPTION
PP HoneycombFMVSS 302, ASTM E84, DIN 4102 can be achieved.
reduce resistance; Refer to standard PPPLASCORE
chemical resistance
PP30-55 pcf
CORE COMPARISON
charts for additional information andArea
reference
points.
= Energy Absorbed
PP Honeycomb 5 pcf
Exposure and evaluation testing is always recommended
to
1.0
10
20
30
40
determine the actual affect to the honeycomb.

0.4

40%
60%

Relative
Relative
PP Honeycomb
Weight 5 pcfDeflection

Area = Energy Absorbed

FLEXURAL RESPONSE
PP Honeycomb

0.8

20%
40%

% SHEAR STRAIN

MATERIAL

1.25

X-PVC

12
10

1.2

20%

Panel Reference Type: 5 pcf

"T x 48" x 48", .02"T aluminum both sides, simply supported, center load.

PERCENT LOSS

DAMPENING RATIO DAMPENING RATIO

14
Most core materials respond similarly
to stress under normal operating loads. As
loading increases the core begins12 to flex to
the increase in shear
Hataccommodate
Section
10
stress on the core. Unlike other core
materials that reach an ultimate yield stress
8
and fail catastrophically, honeycomb,
and in particular Plascore PP Honeycomb,
" PP
" PP
continues to respond and perform.6 This continued Honeycomb
response indicates
the ability
Honeycomb
with
3mm
with
0.5mm
16
4
of the honeycomb to absorb energy
even after
ultimate
yield
strength
failure.
"
Luaun
Glass - PP

Balsa9.5 pcf
VALUE
RATIO
SHEAR
SHEAR
STRESS
STRESS

Continued Performance After Failure

Plywood

0.5

BUOYANCY

DISPLACEMENT
Excellent Cost-to-Performance
Value

14
2

1.0
0.5

Ex
si

PERCENT
PERCENT
LOSSLOSS

0.4

1.5
1.0

Ex
si

Kevlar

0.3

1.5

MATERIAL

Nomex

0.2

with 0.5mm
Glass - PP
both sides

mex

0.1

" PP
Honeycomb
with 0.5mm
" PP
Glass - PP
Honeycomb
both sides

with 3mm
Luaun
both sides

Area = Energy Absorbed

VALUE
VALUE
RATIORATIO

DAMPENING
DAMPENING
RATIORATIO

16

Area = Energy Absorbed

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

DISPLACEMENT

Rela
Co

Core Type

PP Honeycomb

Resin

5 pcf

Balsa

9.5 pcf

Panel Reference Type:

"T x 48" x 48", .02"T aluminum b

14

Area = Energy Absorbed

12
10
0

0.1

0.2

0.3

6
4
2

0.4

0.5
"
PP0.6

0.7

0.8
"
PP0.9

Honeycomb Honeycomb
DISPLACEMENT
with 3mm
Luaun
both sides

"
Plywood

with 0.5mm
Glass - PP
both sides

Relative
Cost

1.5
1.0
0.5

PP Honeycomb
MATERIAL

MATERIAL
Resin

5 pcf

Ex. Panel "T x 48" with

simply supported, cente
Balsa
1
9.5 pcf

Efficient Energy Absorption

Plascore standard 5 pcf PP Honeycomb with non-woven veil

has a Coefficient of Thermal Expansion (CTE) of 8.0 x 10E-5
inch / inch F.

0.2
0.2

0.3
0.3

0.4
0.4

FORCE
FORCE
10
8
6
4
2

0.5
0.5

0.6
0.6

0.7
0.7

0.8
0.8

DISPLACEMENT
DISPLACEMENT

" PP
Honeycomb

0.9
0.9

1
1

" PP
Honeycomb

with 0.5mm
FLEXURAL RESPONSE
with 3mm
Luaun
both sides

"
Plywood
Balsa
9.5 pcf

X-PVC

Glass - PP
both sides

20%
40%

Relative
Cost56%
Rela
Rela
Core Type
Co
Core Type
Co

1.5
60%
1.0

PP Honeycomb
PP Honeycomb
5 pcf

1
1

Balsa
Balsa
9.5 pcf

1.
1

0.5 5 pcf

9.5 pcf

MATERIAL

MATERIAL

Panel Reference Type:

Panel
Reference
Type:
"T
x 48"
xEx.
48",Panel
.02"T
aluminum
bo
"T
x 48" with
"T x 48" x 48", .02"T aluminum bo
simply supported, cent

5 pcf

Hat Section
Hat Section

PERCENT LOSS
VALUE RATIO

0%

PP Honeycomb

BUOYANCY

5 pcf

Area = Energy Absorbed

16
16
14
14
12
12
10
10
8
8
6
6
1.0
4
4
0.8
2
2
0.6
0.4

10

20

30

After Exposure to

Plascore
PP

SOUND ABSORPTION
PLASCORE PP30-5
" PP 5 pcf " PP
PP Honeycomb
" PP
" PP
Honeycomb
Honeycomb
Honeycomb
Honeycomb
with 3mm
with 0.5mm

"
"
Plywood
Plywood

with
3mm
Luaun
Luaun
both
sides
both sides

with
Glass0.5mm
- PP
Glasssides
- PP
both
both sides

Balsa

1000pcf 2000
9.5

3000

FREQUENCY (Hz)

4000

5000

" T

1.0
1.0
40%

MATERIAL
MATERIAL

Ex. Panel "T x 48" with .

Ex. Panel
"T x 48"cente
with
simply
supported,
simply supported, cente

6000

We

After ExposureWe
to 1
After Exposure to 1
Plascore Marine
PP
Plywood
Plascore
Marine
PP
Plywood
0%
0%

Area = Energy Absorbed

20

30

% SHEAR STRAIN

SOUND ABSORPTION
PLASCORE PP30-5

56%

0.5

DENSITY
0.5
60%
lb/ft

X-PVC
Plascore PP Honeycomb's thermal
conductivity = .14 W/m k
BUOYANCY
5 pcf
BUOYANCY
when tested per ASTM C-518. Specific
sandwich panel
performance will vary depending on the definition
of stress
PP Honeycomb
5 pcf
skin material type.
10

Marin
Plywoo

Relative
0%
Relative
Cost
Cost

1.5
1.5
20%

MATERIAL
FLEXURAL
RESPONSE
MATERIAL

Good Thermal Insulation

0.2

We

40

% SHEAR STRAIN

40

PERCENTLOSS
LOSS
ERCENT

Coefficient of
Thermal Expansion

0 14 0.1
0
0.1
12

Marine
Plywood

PP Honeycomb

Plascore PP Honeycomb floats when water temperature and pressure

conditions do not exceed the load carrying capacity of the honeycomb.
Specific gravity of 5 pcf PP Honeycomb with veil = .08; 4 pcf PP Honeycomb
with veil = .065. This equates to a positive buoyancy of approximately 10
times its own weight.

Plascore
PP

Area = Energy Absorbed

Area = Energy Absorbed

VALUERATIO
RATIO
VALUE
PERCENT
LOSS

Provides Positive Buoyancy

After Exposure to 1

16

Resin
Resin
DAMPENING RATIO

PP Honeycomb is available with a non woven facing fused directly to the cell
edge, without any additional films or adhesives. This unique construction
technique optimizes the adhesion of most resins systems to be equal to or
greater than the tensile properties of the non woven itself. The hat section
cell edge allows resin to mechanically lock under its geometry.

We

Hat Section

SHEAR STRESS

Fused for Optimal Tensile Properties

Panel Reference Type:

"T x 48" x 48", .02"T aluminum b

BUOYANCY

DAMPENINGRATIO
RATIO
DAMPENING
SHEAR STRESSABSORPTION COEFFICIENT

Plascore PP Honeycomb, like many other honeycomb structures, is

an efficient constant force absorber. After the honeycomb passes its
compressive yield strength, it continues to absorb energy through further
deformation at a level near 50% of the yield strength. The absorption is
maintained for 75% of its original thickness.

Re
C

Core Type

20%
20%
40%
40%
60%
60%

+
neycomb

Plascore PP Honeycomb when used as a core material in a lightweight

composite sandwich structure provides the user the benefit of a lightweight
and rigid structure along with a vibration dampening medium. t PP
Honeycomb core sandwich panels that are near the same flexural rigidity
to t plywood can be less than the weight and have about to 235% more
dampening. The PP Honeycomb sandwich panel dissipates vibration 2.35
times faster than plywood.

16

VALUE RATIO

Quickly Dissipates Vibration

DAMPENING RATIO
FORCE

Hat Section

56%
56%

PP Honeycomb is specified as follows:

Material - Cell Size - Color - Thickness
Cell size in mm

T = Trimmed
U = Untrimmed

Part dimensions in inches

(T x W x L)

PP1 - 5.0 - N1 - 8 - 01 - T - N - 0.500 - 72.000 - 78.000

Material Type (PP)
(Virgin Grade)
Material density
in lbs/ft.3

Availability:
Densities: 3.5 to 20.0 pcf
Thickness: " - 6" Laminated;
Up to 24" open cell

Storage:

Length: Up to 50'
Width: 72" max.

Color
(Natural)

N = No scoring
S = Scoring
Skin Types:
00 Open Cell
01 Standard Non Woven
10 Standard Non Woven with Film Barrier
20 Infusion Grade
30 Reinforced PP Facings

Tolerances: Length:

Width:

Thickness:

Open Cell:

.125"
.125"
.02"
.03"
w/reinforced PP facings .03"

Density:
10%

Store material flat and horizontal.

Store material in a dry and covered area, protected from UV sunlight and extreme temperatures.
Material may need to be dried prior to use if surface moisture is present.

ISO-9001 Quality
Plascore manufacturing standards meet or exceed North American and
international industry requirements. Plascore, Inc. is ISO-9001 registered,
employing Lean Principles throughout design, manufacturing and
administration. In addition to our proprietary honeycomb manufacturing
process, our value-added capabilities include adhesive development,
CNC machining, powder coating, welding, thermoset and thermoplastic
laminating and assembly. This extensive capability, along with Plascore
JIT, Kanban and sequencing programs, allows us to maintain rigid
quality standards on all components, control project scheduling and
delivery in the manner best suited to the clients specific needs.

Plascore, Inc., employs a quality management system that is AS/EN/JISQ 9100, ISO 9001:2008 and ISO 14001:2004 certified.
IMPORTANT NOTICE: The information contained in these materials regarding Plascores products, processes, or equipment, is
intended to be up to date, accurate, and complete. However, Plascore cannot warrant that this is always the case. Accordingly,
it is a purchasers or users responsibility to perform sufficient testing and evaluation to determine the suitability of Plascores
products for a particular purpose. Information in these materials and product specifications does not constitute an offer to sell.
Your submission of an order to Plascore constitutes an offer to purchase which, if accepted by Plascore, shall be subject to
Plascores terms and conditions of sale. PLASCORE MAKES NO WARRANTIES OF ANY KIND REGARDING THESE MATERIALS
OR INFORMATION, EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Plascore owns and shall retain all worldwide rights in its
intellectual property, and any other trademarks used in these materials are the property of their respective owners. The
information in these materials shall not be construed as an inducement, permission, or recommendation to infringe any patent
or other intellectual property rights of any third parties. 2014 Plascore, Inc. All Rights Reserved. v04.23.14

Corporate Headquarters
Plascore Incorporated
615 N. Fairview St.
Zeeland, MI 49464-0170
USA
Phone
Toll Free
Fax

(616) 772-1220
(800) 630-9257
(616) 772-1289

Web
Email

www.plascore.com
sales@plascore.com

Europe
Plascore GmbH&CoKG
Feldborn 6
D-55444 Waldlaubersheim
Germany
Phone
Fax

+49(0) 6707-9143 0
+49(0) 6707-9143 40

Web
Email

www.plascore.de
sales.europe@plascore.com