Tag Archives: made in the usa

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.

Honeycomb Plywood

patented honeycomb plywood lightweight high strength wood torsion box exposed viewHoneycomb Plywood by Honeycomb Panels could be the best sustainable ecologically responsible building material to surface within the last century that is lightweight, high strength and fully insulated.

Honeycomb Panels’ honeycomb plywood marine ply is so easy to use; any standard wood worker, millwork or wood shop can use our patented honeycomb plywood without any additional skills or equipment, just as though you were using plywood.

Don’t be fooled by its appearance or ease of use. Even though our honeycomb plywood marine ply looks like regular plywood, there is nothing normal about this newest generation of composite materials to hit the woodworking industry.

The boating industry and the U.S. Navy are embracing the attributes of our patented honeycomb plywood to replace marine plywood. Marine plywood is heavy and cannot maintain a high level of flatness or precision, like honeycomb plywood by Honeycomb Panels.

Unlike traditional marine plywood this honeycomb plywood has amazing characteristics that cannot be found elsewhere in any affordable flat building material.

stack of marine grade honeycomb plywood lightweight high strengthFor instance, our patented honeycomb plywood is:

  • Eco-friendly
  • Lightweight
  • High strength
  • Insulated
  • True flat
  • Stay flat
  • Can be waterproof plywood
  • Requires no special handling
  • Eco-friendly

Honeycomb Panels makes our honeycomb plywood right here at our factory in McCleary, Washington in the USA. Our honeycomb plywood may be the only structural building material made in the USA and exported throughout the world.

patented marine grade structural honeycomb plywood for boat builders

Lightweight

At one-third the weight (or less depending on the thickness) this revolutionary new building material helps to reduce energy costs significantly; less expensive to ship across the USA or the world, using less fuel and natural resources with less carbon footprint. At the construction end; less equipment, energy and fuel consumed on-site while saving labor costs and fewer injuries.

High strength

Our honeycomb plywood is stronger than steel pound for pound, testing out at 660 PSI (while other honeycombs are between 10 and 100 PSI) and can be easily increased to over 1400 PSI or more (if necessary to meet your specifications).

Insulated

Honeycomb Panels’ honeycomb plywood is based on their insulated panels’ design that is packed full of solid insulation wall-to-wall between the internal structure grids. The insulation panels can be used as any exterior grade plywood.

True flat

No other high strength affordable insulated building material can be as high precision for true flat surface (with 1000ths of an inch) with little or no variance depending on the desire surface material.

Stay flat

Unlike other flat building materials that may be flat when manufactured or installed, honeycomb plywood by Honeycomb Panels is designed to stay flat for 100 years and guaranteed not to warp, bend or twist for 50 years.

Can be waterproof

Regardless of your intended use, you can use our waterproof plywood honeycomb panels to handle any extreme weather, underwater or water storage applications.

Requires no special handling

This new revolution in building material is completely simple and easy to use just like ordinary plywood. No special saw blades, tools or specialized skills are necessary to bring your designs to life in the most sustainable Eco-friendly way.

In side by side comparison

 

Patented Honeycomb Plywood vs. Traditional Plywood
Lightweight Heavy x
High-strength Moderate strength x
Eco-friendly Not eco-friendly x
Use 10% wood fiber Waste of natural wood fiber x
Manufacture w/little energy Great deal of energy consumed x
Insulated Not insulated x
True flat Will warp x
Moisture proof Absorbent x
Extreme weather proof Will crack, compromise finish x
No size limit Limited to 4×8, 4×10 x
Available in any thickness Limited to 1 1/8 inch x
Waterproof adhesive (crack-free surface) Glues will delaminate due to cracks x
Formaldehyde-free glue Contains formaldehyde x
Available with any skin Limited to wood only x
Made in USA Mostly off-shore import x