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Honeycomb Panels

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.

Honeycomb Panels USA wood torsion box honeycomb core structure foam composite honeycomb panel

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.

Contact Us for more information.

Honeycomb Panels

Honeycomb Panels USAHoneycomb 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.

marine honeycomb panelsHighest 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.

Honeycomb panels aluminum honeycomb panels wood edge optionMarine 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 panelsFiberglass 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.

How Honeycomb Panels Are Made in the USA

patented honeycomb plywood lightweight high strength wood torsion box exposed viewHoneycomb panels by Honeycomb Panels USA use a patented technology that is the perfect combinations of old school artisan craftsmanship and high tech lightweight technology resulting in a composite engineered plywood product that affordably out performs any other honeycomb panel.

Most other traditional honeycomb panels to may achieve the goal of being lighter in weight that other building material – and this has truly been a breakthrough in the last 50 years helping to bolster aerospace technology and other design complications that may have hindered aggressive progress.

stack of marine grade honeycomb plywood lightweight high strengthWhile hugely valuable, traditional honeycomb panels regularly fail strength tests as most have very low PSI strength (i.e., 10 to 100 PSI). It was this deficiency that led inventor Peter Sing on his life long journey to find a structural answer to the issue of lightweight and strength.

The patented process that he discovered required a melding of old and new technologies to develop reinforced structural insulated panels that can achieve 660 PSI (or much higher depending on your required specifications). These resulting panels challenge the laws of physics as we know them.

Also, Sing’s revolutionary honeycomb panels are not only lightweight and high strength, but they are an ecologically friendly and sustainable product made right here in the USA and can be guaranteed for 50 years.

How Honeycomb Panels are Made in the USA

Honeycomb-Panels-Patented-Wood-Torsion-Box-Structure-Made-in-USAUnlike other honeycomb panels that feature non-earth-friendly honeycomb structures that are relatively weak but lightweight, Honeycomb Panels USA honeycomb panels start with a vertical grain natural wood torsion box structure.

This high end lightweight high strength solution has been used by wood craftsmen for thousands of years to develop lightweight, large flat structurally sound panels with the strength to cover long spans with much less risk of failing. The downside of this was that it could not achieve flatness over time due to the nature of the wood that tends to bend, warp and twist due to change in moisture.

see-inside-honeycomb-core-wood-torsion-box-filled-with-foamTo combat these limitations, inventor Sing made two significant modifications to the oridinal torsion box design.

The first was to change the orientation of the wood grain. Traditionally, craftsmen built the torsion box substructure with horizontal wood grain. By flipping and cross cutting the box walls so that their grain was oriented vertically, Sing was able to increase the strength of the torsion box structure many time. But he didn’t stop there.

The second major improvement was to fill the empty spaces within the torsion box structure with rigid foam (which is 90% air) wall to wall, creating a solid, lightweight structural base material that when sandwiched between two stress skins is stronger than steel pound for pound.

honeycomb-panels-usa-green-eco-friendlyEco-Friendly Manufacturing in the USA

The manufacturing of Honeycomb Panels USA uses less energy and manpower, creates very little waste, using the best of natural and recycled materials resulting in an evergreen structural building material made in the USA that will last for centuries without fail.

Aluminum Honeycomb Panels

Honeycomb Panels USA introduces the next generation of patented aluminum honeycomb panels inspired by aerospace, based on traditional woodworking skills resulting in an Eco-friendly high-performance aluminium composite panel that is lightweight and stronger than steel pound for pound.

This is an entirely new aluminum frontier where honeycomb panel sandwich paves the way for the most significant improvement in building materials since SIP panels (Structural Insulated Panels). Patented Honeycomb Panels are by far the most advanced aluminum composite panel amongst the sea of traditional metal panels.

The unique characteristics of Honeycomb Panel USA’s aluminium composite insulated panels has developed the first Reinforced Structural Insulated Panel (RSIP). This new generation of aluminum panels are the first in Honeycomb Panels’ aluminium products that are more lightweight, more high strength and less expensive than other traditional honeycomb panels that are used in high-end aerospace and marine industries.

You might be wondering how strong could these aluminum honeycomb panels be?

Independently tested at the University of Washington patented Honeycomb Panels have a compression strength of 660 PSI. That’s stronger than solid steel pound for pound. (Compare that to any other honeycomb panel, which could have compression strength of 10 to 100 PSI.)

This composite panel news is ringing throughout the metal wall panels industry because our high precision insulated wall panels outperform other sandwich panels in terms of providing affordable Eco-friendly, lightweight and high strength solutions to design issues that architects, designers and engineers have struggled with for years.

Patented Honeycomb Panels’ aluminum honeycomb panels are all based on our natural wood fiber torsion box honeycomb core filled with foam approach to aluminium honeycomb construction. And you might be surprised to discover that patented Honeycomb Panels are made in the USA, right here, in our factory in McCleary, Washington.

We ship, not only throughout the United States and Canada, but our aluminium panels may be the only flat goods building material that is manufactured in the United States and exported worldwide due to its one-of-a-kind unique properties.

Side by side, our space-age futuristic aluminum composite panels leave all other insulated metal panels in the past.

And every once in a while, someone asks us, “How to cut aluminum?”

Here’s the answer: Our aluminum honeycomb panels can be cut to your specifications in any standard wood shop. We have millworks who work with our aluminum honeycomb panels with not extra tools, or blade changes, treating it just like a normal piece of plywood.

So, if you’re looking for a metal panel that has better sound deadening qualities or will act as a temperature barrier with better results than other insulation panels, then you might agree with other architects, designers, high-end millworks, military and aerospace industries, that our patented aluminum honeycomb panels by Honeycomb Panels USA.

Honeycomb Panel

Honeycomb Panels from Sing CoreUnited States-based Honeycomb Panels is proud to manufacture the only Eco-friendly lightweight, high strength honeycomb panels that are made in North America.

The unique honeycomb structure of patented honeycomb panels are completely set apart from other honeycomb core materials, like honeycomb paper, honeycomb cardboard, honeycomb plastic and/or honeycomb metals, like honeycomb aluminum or honeycomb steel.

Honeycomb Panels’ honeycomb panels are configured and manufactured based on an Eco-friendly honeycomb design resulting in the most ecologically sustainable and long-lasting honeycomb panel.

Aluminium Honeycomb Panels 1 inch thick 13 ft span stronger than steel pound for pound

Honeycomb Panels’ high performance aluminum honeycomb panels have superior structural integrity when compared to any other affordable light yet strong honeycomb material. In fact, each Honeycomb Panels’ aluminum honeycomb panel starts with a 660 PSI (stronger than steel pound for pound) and it can be raised in your honeycomb aluminum panels to meet your specifications.

The secret of the superior structural strength of Honeycomb Panels is deep within the honeycomb core material that results in the most significant advancement in honeycomb composite panels in the last century.

Honeycomb-Panel-CoreInside each patented honeycomb panel is a honeycomb wood structure based on torsion box design. Torsion box is a series of wood boxes housed within exterior surface materials as a higher strength alternative to hollow core composite panel. This technology has been around for thousands of years and requires tedious handcraftsmanship.

Our honeycomb core panels feature this wood honeycomb torsion box structure as the starting point. Next up, Honeycomb Panels fills the empty spaces within each wooden box all to wall for an advanced composite recycled foam filled honeycomb that provides a solid foundation for any flat surface building material to be adhered.

When the composite cores are glued to lightweight plywood, the resulting honeycomb wood panels are very strong with unbelievable compression and shear strength.

structural-plywood-torsion-box-foam-core-honeycomb-panel

Honeycomb Panel Double DoorsHoneycomb Panel’s patented honeycomb door is probably the best example of the uncompromising results of this revolutionary super composite honeycomb panel. It is well known within the woodworking craftsmen and millworks that any door over seven feet tall will fail resulting in repeated follow-up calls to the site to fix the door, the hardware or the structure repeatedly over time.

That is because – until now – there just was no way to make a lightweight door that would not warp, bend, twist or crack over time. Thanks to Honeycomb Panels’ honeycomb door core, our doors can measure up to 50 feet and be guaranteed flat and to stay flat for 50 years.

That’s here on the ground. Flying far above our heads you will find aerospace honeycomb panels that have been used for years. Lightweight? Yes. High strength? Hardly. The average aerospace honeycomb panel weighs in at only 10 to 100 PSI (compare that to Honeycomb Panels’ 660+ PSI). Which would you rather have?

honeycomb-panels-aerospace-aircraft-nasa-boeing

That’s why the top aerospace companies, like NASA, Boeing, Lockheed Martin, Lufthansa and the branches of the United States military are now embracing the Honeycomb Panels solution.

Our first of its kind honeycomb sandwich panel can be used not just in aircraft, nor in their hangar doors but in the most unique and wide-ranged honeycomb applications.

And the material options are nearly endless as you can use any surface material to achieve the results – either structurally or visually – to achieve the performance requirements that you desire for nearly any application where weight, strength and structural integrity over long spans may be a concern.