Manufacture of honeycomb panels and structures
A wafer block of aluminium foil core material is stretched into a sheet of hexagonal structure on purpose built, CNC equipment to give a consistent cell dimension. The walls of the cells can be micro-perforated to allow movement of air between adjacent cells, equalising pressure in environments with rapid temperature variations. The expanded core is bonded to the outer facings with a two-part adhesive which is applied in a dedicated computer controlled spray booth facility. This allows close monitoring of coat weights and accurate application to all substrates. The sandwich faces and core are laid up and accurately aligned prior to transferring, by means of roller, table to the press. The final bonding process is done on a heated, hydraulically operated press to ensure uniformity of each panel and is closely controlled to ensure reliability of the bond. The cell size, depth of material, thickness of cell walls and aluminium alloy are all varied to suit specific requirements and tailored to impart the correct, specified properties in the final manufactured units.