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This section provides an overview for honeycomb cores as well as their applications and principles. Also, please take a look at the list of 14 honeycomb core manufacturers and their company rankings. Here are the top-ranked honeycomb core companies as of April, 2025: 1.Corex Honeycomb, 2.SHOWA AIRCRAFT USA, INC., 3.MachineTek LLC.
Table of Contents
Honeycomb Core is a structure consisting of hexagonal columns arranged without gaps.
Honeycomb means beehive, and it is shaped like a beehive with holes. Because more than 90% of its structure is air, it is a lightweight material. It is also strong and shock absorbent, and is used in applications where lightness and strength are required.
Because it has many voids, it also has a rectifying effect that regulates the flow in a certain direction. The rectifying effect is also useful for showcases and wind tunnels.
Honeycomb Core is used in fields where light weight and high rigidity are required, making it an ideal material.
Honeycomb cores are used as structural materials for airplanes and spacecraft, as well as for automobile body parts and bicycle frames. Honeycomb Core is lightweight yet highly rigid, helping to improve fuel efficiency and achieve a high level of safety in aircraft.
It is sometimes used for building exterior panels, interior partition walls, and ceiling materials. Its light weight reduces overall building weight and improves durability against natural disasters such as earthquakes.
May be used for products such as ski boards and snowboards.
Honeycomb Core is very rigid due to its structure. Rigidity is the ability of an object to resist external forces without deformation. Because of its rigidity, Honeycomb Core is not easily deformed even when subjected to impact, and thus exhibits stable performance.
Since most of the interior is air, it also has high thermal insulation properties, making it useful for thermal insulation applications. In particular, paper honeycomb, which has low thermal conductivity of the material itself, exhibits excellent heat insulation properties.
Honeycomb Core includes Aluminum Honeycomb, Aramid Honeycomb, and Paper Honeycomb.
There are a variety of metallic Honeycomb Cores, but aluminum is the lightest of the metals and also has excellent compressive strength. Aluminum foil is formed into a honeycomb structure, and its lightness and strength are used in various fields such as automobiles, trains, and aircraft.
Plastic Honeycomb Core is made from aramid, which has excellent strength and heat resistance. Aramid has high tensile strength, impact resistance, light weight, and flexibility. Aramid also offers fire resistance and chemical and thermal stability.
They are increasingly used in aircraft, replacing aluminum honeycomb. However, it also has disadvantages such as dimensional change due to moisture absorption and high cost.
Paper is molded into a honeycomb structure. Kraft paper is used. It is lighter than aluminum and aramid. It is also an environmentally friendly material because it is recyclable. It is used in construction materials, packing materials, and partitions for display spaces.
Being paper, it has weaknesses in water resistance and heat stability. Currently, when compensating for the weakness, there is a method of adding a porous silica film to the surface.
Honeycomb structures are fabricated by gluing sheets together. There are two methods of manufacturing honeycomb cores: the tension method and the corrugated method, with the tension method being the most common. The principle of the tension method is explained here.
First, the required amount of material is cut from a roll of raw material and formed into sheets. The cut sheets are degreased as a pretreatment. In the case of metallic materials, etching is performed.
After the pretreatment is completed, adhesive is applied to the sheet. The adhesive is not applied to the entire sheet, but rather to areas that are coated and areas that are not coated in a linear pattern at regular intervals. Layers of adhesive-coated sheets are stacked on top of each other.
By stretching the layered sheets (unfolding them from their folded state), the parts not coated with adhesive are lifted up to form the Honeycomb Core. Depending on the application, a sandwich panel structure may be formed by attaching a surface material to both sides of the Honeycomb Core. In this case, surface treatment is performed on the surfaces to be laminated.
*Including some distributors, etc.
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SHOWA AIRCRAFT USA, INC., a company founded in 1997 and headquartered in Redmond Washington is a manufacturer in the aviation industry. The company is a subsidiary of SHOWA AIRCRAFT CO., LTD. Specializing in aircraft products and honeycombs, the company established itself as a source for galleys, PMA parts, and honeycomb cores and panels. Its products cater to diverse aviation needs, supplying its products to packaging, airlines, maintenance facilities, and aircraft operators.
ARGOSY INTERNATIONAL INC., a company founded in 1988 and headquartered in New York City, United States, is a manufacturer of honeycomb and a supplier of products for aerospace and commercial applications. The company specializes in supplying composite materials, adhesives, specialty chemicals, and service solutions to aerospace original equipment manufacturers, airlines, overhaul facilities and maintenance shops. It has an approved ISO9001, AS9120 and AS9100 quality management system which demonstrates its capabilities of supplying customers with products and services.
RelCore Composites Inc., founded in 2015 and headquartered in Cannon Road, Northfield, Minnesota, is a manufacturer of aluminum honeycomb core. The company’s product is utilized for lightweight applications that require flexural strength, structural backup, and impact resistance. It offers unexpanded blocks, unexpanded slices, untrimmed expanded sheets, and cut-to-size expanded sheets. It also provides a corrosion-resistant barrier for standard corrosion protection for cores exposed to extreme environments. The company’s corrosion-inhibitor coating offers superior protection and is certified to AMS-7438 requirements.
Plascore, Inc. headquartered in Zeeland, Michigan, and has sales offices throughout the world, are manufacturers of honeycombs of various metal and plastic materials. The portfolio of the company consists of honeycombs made from aluminum, aramid fiber, stainless steel, thermoplastic, and more. The company also creates modular cleanroom systems and energy absorbers. Honeycomb Core of the company is the OEM choice for manufacturing composite boards and assemblies used in automotive, rail, aviation, marine, and exhibition markets. The company is accredited with AS9 100 Certification, ISO 14001 EMS Certification, ISO 9001 Certification, and many more.
Prime Laminating, Inc., established in 1991, and headquartered in Attleboro Falls, Massachusetts, USA, is a custom manufacturer of composite panels. The company's products includes integrated enclosures, radiation shielding, architectural panels, and laminating honeycomb panels, which caters to industries such as medical, radiation management, retail display, and security and detection industries. Its products are used for applications such as protective enclosures, radiation containment, architectural design, and structural reinforcement in various industries.
MachineTek LLC, founded in Carlsbad, CA in 1992 is a manufacturer of honeycomb and foam core fabrication solutions for aerospace composite companies. The company's product portfolio includes Honeycomb fabrication, Honeycomb forming, Honeycomb machining, Foam Core Machining and Bonded Panel Machining. The company serves industries such as Oil and Gas, Aerospace and Defense, Automotive and Transportation, Construction, and Power Generation. The company provides services such as Product Selection Guidance, Engineering Support, and Custom Manufacturing.
HONYLITE, established in 2009 and headquartered in Greater Noida, Uttar Pradesh, India, is a manufacturer specializing in aluminum honeycomb cores and panels. The company excels in design, workmanship, and customer satisfaction. Its laminated honeycomb panels offers strength-to-weight ratios, benefiting industries worldwide. HONYLITE's extensive product line encompasses various types of honeycomb panels, including aluminum, stainless steel, FRP, HPL, and more. They are ISO 9001:2015 certified and also offer value-added features and customization options. They provide services to a wide range of Industries including Railways, Marine, Aviation, Aerospace, Construction, Flow Straightener, Energy Absorption, Wind Energy, Acoustics, Defence.
ThermHex Waben GmbH, a company founded in and headquartered in Halle, Germany, is a manufacturer of honeycomb cores. Specializing in producing lightweight, durable thermoplastic honeycomb cores, the company caters to diverse industries like automotive, aerospace, and construction. Capable of precision engineering, the company’s products find application in sandwich panels for enhanced structural integrity, sound insulation, and thermal efficiency. With ISO 9001 and 14001 certifications, the company ensures industrial quality standards and sustainability.
CEL Components was established in 1992 and is based in Pompano Castenaso, Italy, as a manufacturer of sandwich and honeycomb panels. The company's product list comprises aluminum honeycomb, PVC 40 foam core, COMPOCEL W, and aluminium powder, among others. The products find applications in sandwich panels for flooring, roofing, doors, partitions, facades, and surfaces for automatic machinery, as well as in interior design, furniture, fireworks, metallic varnish, pigments for coatings, and additives for composites. The company serves various industries, including marine, sports, automotive, wind energy, shipbuilding, and railways.
Yoj Pack Kraft, a company founded in 2000 and headquartered in Pune, Maharashtra, India, is a manufacturer and supplier of honeycomb products and solutions. The company specializes in various types of honeycombs utilized in furniture, exhibitions, and packaging. The company’s product range includes honeycomb door fillings, panels, pallets, and edge support. Its products are utilized to substitute for corrugated sheets, thermocol, foam sheets, plastic panels, and tube boards, promoting eco-friendly alternative products.
Industrial Packaging Corp, founded in 1989 and headquartered in Tomahawk, Wisconsin, is a manufacturer of packaging products and related solutions. The company specializes in producing a diverse range of packaging solutions tailored towards various industrial applications. Its scope includes corrugated pads, cardboard designs, honeycomb pads, and honeycomb cores made from paper produced by mills that using recycled fibers. From corrugated packaging to honeycomb packaging materials, its products cater to different sectors including manufacturing, logistics, and agriculture industries.
Koshii America, Inc., founded in 1996, is a manufacturer of passenger rail car interiors, headquartered in Poughkeepsie, New York. They manufacture various interior components for vehicles, including Plymetal flooring, balsa core panels, ceiling panels, and engineers' cab doors. They integrate close tolerance machining to ensure a precise fit within the assembly panel. The company also provides assembly services for various components to meet the stringent requirements of the rail industry, ensuring the safety of operations.
Corex Honeycomb headquartered in Cambridgeshire, United Kingdom, established in 1995 is a manufacturer of aluminum honeycomb core and supplier of the same to many industries worldwide, offering a wealth of experience and expertise together with a global distribution network. The portfolio of the company includes: “SuperFlex,” a flexible aluminum honeycomb, Nomex and Kevlar aramid paper honeycomb, and Tubus Waben polypropylene honeycomb. The company manufactures aluminum alloy grades 3003 and 5052, depending on the application; full blocks or cut slices; perforated or non-perforated; corrosion treated or untreated; drilled; expanded or unexpanded.
Ranking as of April 2025
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Corex Honeycomb |
11.7%
|
| 2 | SHOWA AIRCRAFT USA, INC. |
10.4%
|
| 3 | Plascore, Inc. |
10.1%
|
| 4 | Industrial Packaging Corp |
8.2%
|
| 5 | MachineTek LLC |
8.2%
|
| 6 | ARGOSY INTERNATIONAL INC. |
8.0%
|
| 7 | HONYLITE |
8.0%
|
| 8 | ThermHex Waben GmbH |
7.7%
|
| 9 | CEL Components |
6.4%
|
| 10 | RelCore Composites Inc. |
6.1%
|
Derivation Method
The ranking is calculated based on the click share within the honeycomb core page as of April 2025. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
6 | 60.0% |
|
India
|
1 | 10.0% |
|
Germany
|
1 | 10.0% |
|
Italy
|
1 | 10.0% |
|
United Kingdom
|
1 | 10.0% |
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