CFRT honeycomb panels are sandwich panels made of thermoplastic polypropylene (PP) honeycomb core material and continuous fiber reinforced thermoplastic (CFRT) skin. They break free from the constraints of traditional thermosetting resins and chemical adhesives, representing a new generation of environmentally friendly and efficient structural materials. This product achieves a good balance between lightweight, mechanical strength, water resistance, durability, and processability. Furthermore, it is a renewable material, 100% recyclable at the end of its service life, aligning with the vision of sustainable economic development.

Outstanding Performance

• Lightweight

The honeycomb hollow structure significantly reduces the overall weight of the panel. With a density much lower than solid wood and metal, it effectively reduces weight while lowering transportation and load-bearing requirements.

• High Strength

Excellent bending, compressive, and impact resistance, providing reliable structural performance in demanding applications.

• Water and Moisture Resistant

The all-thermoplastic construction does not absorb water and is resistant to moisture-induced swelling and mold growth. It withstands water vapor and maintains stable performance in humid environments.

• Corrosion and Aging Resistant

The polypropylene-based material offers excellent corrosion resistance and withstands exposure to acids and alkalis, contributing to a longer service life.

• Delamination-Free

The layers are bonded through hot-melt fusion, providing high interfacial bonding strength and minimizing the risk of delamination and cracking during long-term use.

• Eco-Friendly and Recyclable

The all-thermoplastic system contains no liquid adhesives, making the panels easier to recycle and reuse at the end of their service life.

Structural Diagram

Structural Analysis

01. CFRT Sheets (Continuous Fiber Reinforced Thermoplastic Skin)

CFRT sheets are manufactured by impregnating continuous glass fibers with thermoplastic resin to form unidirectional tapes (UD tapes). These tapes are then stacked in multiple layers at different fiber orientations according to the required load-bearing requirements and consolidated through continuous high-pressure hot pressing. The continuous glass fibers running throughout the sheet form a strong structural “skeleton,” delivering significantly superior tensile strength and flexural performance compared with short-fiber-reinforced materials or continuous nonwoven fiber-reinforced materials.

02. PP Honeycomb Core

High-quality thermoplastic polypropylene (PP) is continuously extruded to form a circular-cell honeycomb structure. This honeycomb structure provides an excellent strength-to-weight ratio, reducing the overall weight of the panel while enhancing its flexural rigidity and compressive strength. It serves as a core structural component for achieving lightweight panel construction.

How Are CFRT Honeycomb Panels Manufactured?

Traditional composite sandwich panels typically rely on epoxy resin or polyurethane liquid adhesives for cold or hot pressing and bonding. Over time, this adhesive bonding method may lead to adhesive-layer aging, delamination, and VOC emissions. CFRT Honeycomb Panels, by contrast, are manufactured using a completely glue-free hot-melt fusion lamination technology.

01. Interfacial Melting

Through a precisely temperature-controlled high-frequency heating system, the polypropylene resin on the inner surface of the CFRT skin and the surface layer of the PP honeycomb core are rapidly heated to a molten state. Alternatively, a compatible hot-melt adhesive film can be introduced between the layers.

02. Molecular Chain Diffusion and Fusion

Under the high pressure applied by continuous laminating rollers, the skin and honeycomb core undergo molecular-level diffusion and fusion at the interface. After cooling and solidification, the layers form a strong, integrated structure without the need for conventional liquid adhesives.

OEM & ODM CFRT Honeycomb Panel Solutions

TOPOLO is a professional manufacturer of thermoplastic honeycomb sandwich panels, providing OEM and ODM customized solutions to customers worldwide. Backed by advanced thermoplastic composite lamination production lines, TOPOLO is capable of efficiently manufacturing high-quality CFRT honeycomb panels tailored to a wide range of application requirements.

The following customization options are available:

Customization Option	Available Specifications
Panel Size	Up to 12 m × 2.8 m
Panel Thickness	10–150 mm
CFRT Skin Thickness	0.7–2.0 mm
PP Honeycomb Cell Size	6 / 8 / 10 / 12 / 16 mm
PP Honeycomb Core Density	60–120 kg/m³
Surface Finish	Glossy, Matte, Embossed, Patterned
Color	RAL color series
Mechanical Properties	Subject to actual test results

Versatile Surface Finishes

CFRT honeycomb panels support a wide range of surface treatments and can be customized with different colors, textures, gloss levels, and functional finishes according to specific application requirements. This flexibility enables the panels to meet diverse needs for decoration, wear resistance, slip resistance, scratch resistance, and easy cleaning across various applications.

Wide Applications of CFRT Honeycomb Panels

As a high-performance lightweight thermoplastic composite material, CFRT honeycomb panels are gradually replacing traditional materials such as wood, steel, and aluminum sheets. They are widely used in applications where weight reduction is a priority. Whether used as a surface panel or a structural substrate, CFRT honeycomb panels deliver excellent overall performance.

For more information on our applications, please contact us to obtain customized solutions.

PP Honeycomb Sandwich Panel Series