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Aluminum Honeycomb

Aluminum honeycomb possesses an excellent strength to weight ratio and is used where rigid and lightweight properties are required.  Its core resembles stacked hexagons, or natural honeycomb, from where it gets its name. It is produced by applying evenly spaced adhesive strips to a stack of aluminum foils.  The stack is then pulled apart in a controlled process to give the expanded, open nature of the honeycomb. If required, a cladding face is then applied.

Aluminum honeycomb is used in various fields including:

  • Automotive
  • Aerospace
  • Marine
  • Energy absorption
  • Flow straightening

Characteristics of aluminum honeycomb include:

  • Lightweight
  • Corrosion resistant
  • Available with or without cladding
  • Rigid in 3 axes when clad
  • Rigid in 1 axis and flexible in the other two when not clad

Alternatives to aluminum include polypropylene and polyaramid (Nomex).


Video of aluminum honeycomb being tested at the Transport Research Laboratory as part of the University of Birmingham’s Formula Student race car project in 2013.