Honeycomb Panels USA Sing core composite panels are lightweight, strong, durable, and rigid. Our team of professional designers and fabricators can manufacture custom-made panel in a wide range of sizes for one-of-a kind design applications.
We keep in stock the most popular standard-sized panels and can readily manufacture other standard-sized panels with short turn-around times to help you meet your critical deadlines.
Honeycomb Panels USA specializes in finding custom solutions for your design needs.
Patented Honeycomb Panels are the secret ingredient for many architects and designers to use in making original and custom doors and tables. Using a patented honeycomb panel substrate (constructed with an external or internal frame) different veneers (wood, stone, metals, etc. ) can be applied making unique doors and tables that are lightweight, flat, and rigid.
Reasons to use Honeycomb Panels USA for custom doors include:
A 4′ x 8′ piece of plywood 3/4″ thick can weigh 70 to 90 pounds, but a 4′ x 8′ sandwich honeycomb panel with aluminum facings weighs approximately less than 50 pounds, making the options for large or thick doors a cost-effective choice for designers and contractors.
The panels can be manufactured with an internal or external frame. Internal frame panels are a bit stronger, but may not be necessary for your application.
Hard points can be embedded in the panel during manufacturing for secure hardware attachment.
By using patented Honeycomb Panels USA as the substrate, very large (up to 21 feet wide and 32 feet tall) and very thick (up to 6 inches) doors can be manufactured. Wider doors can be made by splicing; call us to discuss your unique design needs.
We stock some standard size honeycomb panels and continue to expand our stock panel inventory.
Currently we stock the following honeycomb panels (Please call to inquire price and availability; in-stock panels ship in three business days):
Specializing in finding custom solutions for your design needs, Honeycomb Panels can incorporate multiple features into your panels to meet your project requirements. In addition to customized panel thickness, honeycomb cell size, and aluminum facing finish, we offer:
Mechanical design and drafting
Hard Points or blocking
Fastener and pin installation
Panel perimeters in the following materials:
LVL (Laminated Veneer Lumber)
Rigid Foam PVC
This is only a sample of the services and panel features that we offer. Call us to discuss your particular panel customization needs.
Standard panels come in “standard” aluminum sheet sizes that are 4 to 6 foot wide.
Panel thickness (measured in inches):
Standard panels can be manufactured to customer thickness specifications from 1/4 inch to 6 inches thick. For panels greater than 6 inches thick, multiple panels can be combined to create the desired thickness. Lengths can be manufactured up to 19.5 feet.
Available aluminum honeycomb cell sizes: 1/4″, 3/8″, 1/2″, 3/4″, and 1″.
Aluminum facing thickness range from .020 to .063 inches. For information on additional facing choices and other options, visit the Custom Panels page.
Welcome to Honeycomb Panels USA, the only Eco-friendly manufacturer of the most lightweight high-strength honeycomb panels in the United States.
Honeycomb Panels USA manufactures a patented new generation of honeycomb panel that outperforms all other honeycomb panels anywhere.
How to make the best honeycomb panels in the world
The secret behind making the best honeycomb panels in the world, begins with the internal structure of the honeycomb panels themselves. Our honeycomb structure is made of natural vertical wood grain fiber in a torsion box configuration. This creates an enormously high strength torsion box honeycomb panel… but Honeycomb Panels USA does not stop there…
Patented torsion box honeycomb panels go even further by filling the empty spaces of the torsion box honeycomb structure wall to wall with rigid recycled foam. Sandwiched between two stress skins using waterproof formaldehyde-free adhesive creates the most lightweight, high strength solid composite core honeycomb panels ever invented.
How strong are Honeycomb Panels USA panels?
Honeycomb Panels USA panels have been independently tested at Washington State University at 660 PSI (stronger than steel pound for pound); compare that to other honeycomb panels commonly used in the aerospace industry that test at only 10 to 100 PSI with very little shear strength.
They are so strong, in fact, that you can traverse long spans without much support, which is why the United States Military, NASA, marine and aerospace manufacturers rely on Honeycomb Panels USA for the strongest most lightweight panels.
Insulated Honeycomb Panels
Honeycomb Panels USA panels have a natural insulation quality built in to the structure itself that imbues each honeycomb panel with insulation from heat, cold and barometric environments with a rating of R-3.5 or R-6.5 per square inch of honeycomb panel thickness.
This insulation also creates a sound barrier with its sound deadening qualities for increased privacy and noise control in industrial applications.
Large and Oversized Honeycomb Panel Projects
One of the unique uses of Honeycomb Panels USA’s torsion box honeycomb panels is in the large/oversize division of projects around the world.
Weighing in at a fraction of other building materials, our honeycomb panels can be created in sizes up to 40 ft. and up. While size and weight are considerations for shipping abilities (the United States Military has ways to overcome super large panel shipments that may not be available to the average commercial contractor, distributor or supplier). Honeycomb Panels USA has devised a system for creating modular honeycomb panels that can be shipped as multiple components and assembled on site while retaining complete structural integrity and can be guaranteed to be completely flat following assembly and for a minimum of 50 years without fail.
50 Year Honeycomb Panels USA Guarantee
That’s right. Only Honeycomb Panels USA can offer a true flat guarantee that states that your premium honeycomb panels will be true flat and will stay flat, will not warp, bend, twist, cup or otherwise fail for 50 years, backed in writing.
Honeycomb panels by Honeycomb Panels USA are the most lightweight, high strength insulated honeycomb panels and they are also good for the earth.
How to make honeycomb panels
Our honeycomb panels start with patented torsion box honeycomb core. The torsion box structure is made of vertical grain natural wood fiber; this inner structure honeycomb grid provides superior structure strength. But we don’t stop there; next we filly the open spaced wall to wall with rigid recycled foam providing additional strength and insulation while remaining lightweight. Finally we sandwich the solid composite honeycomb core between two stress skins.
Highest strength honeycomb panels
It’s no surprise that Honeycomb Panel USA’s honeycomb panels can be found beneath the sea (US Navy), in outer space (NASA) and everywhere in between. Why? Because no other affordable lightweight honeycomb panel is as strong. For instance, most aircraft honeycomb panels are only rated from 10 to 100 PSI, while Honeycomb Panels USA honeycomb panels are rated at 660 PSI and they are the only Eco-friendly honeycomb panels proudly made in the USA.
Lightest weight honeycomb panels
Your project can fly high using Honeycomb Panels USA’s honeycomb board. Weighing in at a fraction of the weight of other solid honeycomb panels, our honeycomb grid material is the secret ingredient in these aircraft honeycomb panels that outperform any other aerospace honeycomb panel thereby redefining aircraft honeycomb.
Marine honeycomb panels
Even though the aerospace industry loved the idea of honeycomb panels you might be surprised to discover that honeycomb panels are being found increasingly amongst the marine industry in boat making, ship building, submarines and air craft carriers due to its lightweight, airtight, waterproof and stronger than steel pound for pound.
Aluminum honeycomb panels
Our next most popular honeycomb panels are our aluminum honeycomb panels. They are the strongest Eco-friendly lightweight honeycomb panels and can be completely encapsulated in aluminum per your specifications for the best aluminum honeycomb sheet. Make sure your aluminum honeycomb panel features our patented torsion box honeycomb grid.
Fiberglass honeycomb panels
Close behind our aluminum honeycomb panel is our fiberglass honeycomb panel available in fiberglass or FRP (fiberglass reinforced plastic). Enjoy the lightweight high strength American made honeycomb panels from Honeycomb Panels USA.
Where can I get Honeycomb Panels USA panels?
You can get our patented technology infused honeycomb panels from your favorite home improvement center, lumber yard, sheet goods supplier or anywhere you find honeycomb panels for sale. See your favorite supplier for your best honeycomb price.
The Honeycomb Board panel is a true revolution in the building materials industry and may be the most significant technological breakthrough in the last Century.
No other building material is so versatile with attributes that carry over into your product creation enabling you to build anything lightweight, high strength and Eco-friendly.
Stop being limited by statistics represented by outdated building materials… Build anything… and bring your dreams to life with Sing Sandwich panels – On Sale Now.
You Can Create Anything in Any Size with Honeycomb Board Panels is Easy as A, B, C
A. Add your own skin
Using Honeycomb Boards as substrate you can cold-press nearly any flat exterior surface material to achieve your specifications in both appearance and performance while maintaining high strength and lightweight characteristics.
B. Band the edges
The Honeycomb Board has open edges so that the Core material and wood torsion box material is exposed to the naked eye. Simple edge-banding is easy and hides the exposed patented core and take on the appearance of solid wood (or material of choice).
C. Combine for any size
Instead of ordering expensive large sandwich panels, you can combine several standard-sized (4×8) Honeycomb Board Panels, joining them yourself to create any size desired and saving you the added expense of custom manufactured oversized panels.
D. Designs come to life
With the increased versatility of Honeycomb Board panel’s ability to take on any characteristics that you desire, by simply covering, edge-banding and assembling to make any size required, you have unlimited options to truly create anything you want.
Here are some photos of what people are making with Honeycomb Board panels… What will you do?
Only Honeycomb Panel USA’s Honeycomb Board can make all your dreams come to life*.
* = Especially designs that would have been limited due to the heavy weight or weakness of previously available building materials.
You will be surprised by the insulated Eco-friendly, light weight, super-strength honeycomb board panel.
Standard sizes, thicknesses, faces and quantities are limited to those listed. For other dimensions and/or options please contact us for more information.
Standard Honeycomb Board Panel Details:
Dimension: 4 ft x 8 ft
Thickness: 1 inch
Standard plywood or HPL surface*
3×3″ torsion box structural grids
* = subject to availability/stock on-hand
HONEYCOMB BOARD 1/2 PRICE SALE*
Regular Price: $256
Sale Price: $128*
Honeycomb Board 1/2 Price Sale expires: Dec. 31, 2014
You Can Create Anything in Any Size with Honeycomb Board is Easy as A, B, C
A. Add your own skin
Using Honeycomb Board as substrate you can cold-press nearly any flat exterior surface material to achieve your specifications in both appearance and performance while maintaining high strength and lightweight characteristics.
B. Band the edges
The Honeycomb Board has open edges so that the Sing Core material and wood torsion box material is exposed to the naked eye. Simple edge-banding is easy and hides the exposed patented core and take on the appearance of solid wood (or material of choice).
C. Combine for any size
Instead of ordering expensive large sandwich panels, you can combine several standard-sized (4×8) Honeycomb Boards, joining them yourself to create any size desired and saving you the added expense of custom manufactured oversized panels.
D. Designs come to life
With the increased versatility of Honeycomb Board’s ability to take on any characteristics that you desire, by simply covering, edge-banding and assembling to make any size required, you have unlimited options to truly create anything you want.
1. What is a Honeycomb Board Panel?
A Honeycomb Board panel consists of patented Sing Core sandwiched between two exterior sheets of flat building material resulting in the strongest lightweight low-cost panel in the world. Honeycomb Board panels are so versatile, they have hundreds of applications. For more information on the Honeycomb Boards, see: Honeycomb Panels.
2. Honeycomb Board Panel Applications
The 1.52 inch thick Honeycomb Board is our most popular door core material; after adding 1/8 inch skins, you have the perfect door thickness. You could use these patented honeycomb board panels to build your own engineered lumber in your shop, or
Construct a tiny house
World’s smallest house
Make a door
Use as flooring
Trade show displays
… and so much more …
3. Why Build with Honeycomb Board Panels?
There are so many things that you can create with Honeycomb Board panels, knowing that by doing so, your end product will be manufactured with a True Green Eco-friendly material that is lightweight, stronger than steel pound for pound with built-in insulation.
Here at Honeycomb Panels USA, we make the world’s best Eco-friendly oversize doors that are lightweight, stronger than any other comparable material, and are true flat. No one else could accomplish this feat if not for the Sing Core composite secret ingredient.
High-end formaldehyde-free adhesion
Honeycomb Board panels are constructed using the most responsible use of natural wood from nature and expensive structural urethane glue that is formaldehyde-free and water resistant.
Other applications such as: insulated flooring, moveable partition walls, loft floors, table top substrate, counter top substrate and so much more.
4. How to Build with Honeycomb Board Panels
Create Hardwood Lumber On Demand
By having a quantity of Honeycomb Board panels on hand, you can create your own hardwood lumber, posts and beams, furniture parts, metal composite building materials at your location, when you want it, as you need it! Having a Honeycomb Board panel inventory is the secret weapon in exclusive high-end millworks.
Create any size panel you want
Due to its extreme versatility, Honeycomb Board panels can be ripped and cut just like any other plywood-type building material. Cut into strips and glue together to make your own posts and beams, then finish them in any exterior material that meets the specifications of your project.
Honeycomb Board Substrate
One of the most popular uses of the patented Honeycomb Board panel is as substrate material. The most popular use is as door core but is also popular as substrate for countertops, table tops, flooring, walls, ceilings and in a wide variety of office and home furniture.
Applying Exterior Surface Material
Applying exterior surface materials to the Honeycomb Board is simple and easy. Most any laminated building material can be adhered to your Honeycomb Board by cold-pressing with standard wood/carpenter glue or contact cement. Certain contact cements are best when adhering plastics or vinyl materials to your Honeycomb Board facings; and peel-and-stick vinyl coverings are gaining in popularity making it easy to change appearance of your Honeycomb Board panels instantaneously.
Joining Honeycomb Board Panels
Joining Honeycomb Board panels is much less complicated that you might think. Imagine being able to build a structure without the need of any lumber-frame. We have people building entire homes without being framed, by simply joining Honeycomb Board panels that are pre-insulated with built-in structure torsion box frame making these lightweight panels stronger than steel pound for pound.
How Do People Join the Honeycomb Board Panels?
Unlike other 4×8 sheets of building materials, like plywood, particle board or other common substrate materials; Honeycomb Board is straight due to it’s patented internal structure design, and therefore easily joined with out additional framing materials. Some people do join using an H channel system, though most simply urethane-glue the straight panels together. After the glue has dried, any excess glue is removed by sanding; then finish just like you would any other wood-based building material. Urethane glue provides a better more solid, ling-lasting and weatherproof connecting result than nails or screws used in conventional building methods.
Now you can have the convenience of Honeycomb Board panels – that are superior when compared to other materials – in stock at your location at huge savings due to this one-time offer without using promo codes.
Want large panels?
Certainly, when we build large panels, we can certify and guarantee them as true flat, using our seamless technology. But, you can manufacture your own oversized panels by patching as many Honeycomb Board panels as you need to achieve the desired dimensions of your project at your location.
Want an even better deal?
Special truckload price inquiries will also receive an extra discount for quantity. Contact us to take advantage of our special-priced outlet offer.
Almost any DIY person can build a 8 x 16 Tiny House in their back yard w/22 pieces of Honeycomb Board Panels (see the strength of this 1 inch thick Honeycomb Board shown in photo).
Shipping times may vary. This special price is based on cumulative bulk order(s) i.e., your order will be combined with other orders and shipped following production run.