Core Materials for Composites

Composite core materials serve as the central structural component in composite structures, providing stability, strength, and support while often contributing to the overall lightweight nature of the final product. These cores, typically made of materials like foam, honeycomb structures, or balsa wood, are sandwiched between layers of composite skins to form a composite panel. Their inherent properties—such as high strength-to-weight ratios, excellent insulation, and impact resistance—make them integral in various industries, including marine, aerospace, and construction, where weight reduction and structural integrity are paramount. The choice of core material plays a crucial role in determining the performance and characteristics of the composite structure.

Composites end markets: New space (2025)
Prepregs

Composites end markets: New space (2025)

Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.

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Wickert Hydraulic Presses
Kent Pultrusion

Latest Core Articles

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Core

Airbus to design, build ESA ExoMars rover lander platform

The resurrected Rosalind Franklin composite rover mission’s key systems will be upgraded with support from the TAS, ESA and NASA for a planned launch in 2028.

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Epoxies

Norco delivers GFRP hard hulled riverine craft for BAE Systems

Norco’s broad-ranging materials and manufacturing expertise revitalize UK MOD legacy craft, providing a solution for future defense and communications sector projects.

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JEC

PVC foam core combines reliability with environmental sustainability

JEC World 2025: Maricell will have its own branded booth to present three new MYcell products targeting various sector requirements and sustainability initiatives.

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JEC

Composite, adhesive and core solutions focus on performance, reducing carbon footprint

JEC World 2025: Gurit celebrates 190 years with a display of its product variety — from Spabond 400, resins, prepregs and Gurit PET to BalsaFlex, Opticore and other core systems.

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Core

Diab achieves mass balance certification, introduces bio-based PVC

As part of its ISCC Plus certification, guaranteeing traceability, Diab is basing all Advanced kits on mass-balanced fossil-free PVC starting in March.

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JEC

Composites portfolio targets thermoplastics, flame-retardant solutions 

JEC World 2025: Avient showcases its portfolio of advanced composites and engineered fiber solutions, including its Hammerhead FR flame-retardant thermoplastic composite panels.

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Knowledge Centers

CompositesWorld Collections
CompositesWorld Collections

CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.

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CW Tech Days: Sustainability
CW Tech Days: Sustainability

This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.

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CW Tech Days: Bonding and Welding
CW Tech Days: Bonding and Welding

Join us for insights into advanced bonding techniques and welding processes for composite materials to ensure durability and structural integrity.

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Wabash
Industrial CNC Routers
ELFOAM rigid foam products
Master Bond Epoxy Adhesives
Airtech International Inc.

Latest Core News And Updates

Core

Easy-to-process particle foam targets composite foam core needs

JEC World 2025: Asahi Kasei presents SunForce, a modified polyphenylene ether (mPPE) particle beads foam featuring high heat resistance and low water absorption.

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Defense

Hexcel core supports Boeing’s development of the MQ-25 Stingray

HRH-302 honeycomb core material, currently under evaluation for use around the UAV’s high-temperature exhaust nozzle, could considerably extend its range.

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Sustainability

Melker of Sweden accomplishes sea kayak with 100% sustainable composite construction

Built with ampliTex flax fabrics, a solid cork core and Sicomin plant-based resins, the company’s Värmdö kayak model highlights an environmentally conscious design for paddlers of all levels.

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Glass Fibers

Composite Kape skateboard delivers durability, pop

Collaborative effort between KraussMaffei and entrepreneur Peter Karacsonyi led to the Vanguard, an in-situ polymerized board comprising fiberglass sandwich composites with a recyclable polyamide. 

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Sustainability

Diab, Brødrene AA celebrate 50 years of composite ferry innovation, sustainability

Partners reflect on the increasing use of Diab foam core and GFRP, CFRP composites in Brødrene AA construction over the years, resulting in lightweight, high-performance and efficient marine craft.

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Core

Hexcel introduces mid-temp Flex-Core HRH-302 honeycomb core

Bismaleimide (BMI) option to serve complex curvatures and thermal management needs of military, commercial and UAM aircraft.

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Large Scale Additive Manufacturing
Your partner for advanced composite cores
America's Composite and Advanced Materials Expo
ColorForm multi-component injection
Release agents and process chemical specialties

Featured Posts

PUR composite sandwich panels for 3D automotive parts, high-volume panels and more

At its U.S. sites, Ascorium produces glass fiber/PUR 3D parts via semi-automated molding, high-volume flat panels via a continuous line while working toward bio-based PUR and recycling.

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Core

VIDEO: Precision fabrication of honeycomb materials

MachineTek showcases its precision fabrication of honeycomb materials at CAMX 2024.

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Work In Progress

Composite SIPs for more affordable, efficient and sustainable buildings

LiteSIP panels and modules enable framing in days, cutting structural labor and total cost by up to 70% and 30%, respectively, while increasing energy efficiency and durability.

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Troubleshooter

Guidance for the thermoforming process

A briefing on some of the common foam core material types, forming methods and tooling requirements.

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Electronics

Aviation-specific battery system uses advanced composites to address electric, hybrid flight

BOLDair’s composite enclosure, compression structures and thermal runaway management enables high-performance electric energy storage.

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Prepregs

Bio-based, fire-resistant composites become mainstream

Projects use Duplicor prepreg panels with highest Euroclass B fire performance without fire retardants for reduced weight, CO2 footprint in sustainable yet affordable roofs, high-rise façades and modular housing.

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HEATCON Composite Systems
Ancamine® 2337M
Composites One - distributor
Release agents and process chemical specialties
Carbon Fiber 2025