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.

Post Cure: Composite seaglider craft redefine coastal transportation operations
Post Cure

Post Cure: Composite seaglider craft redefine coastal transportation operations

The Viceroy all-electric flagship seaglider being developed by REGENT Craft in Rhode Island operates exclusively over water.  

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Latest Core Articles

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Aerospace

Cutting 100 pounds, certification time for the X-59 nose cone

Swift Engineering used HyperX software to remove 100 pounds from 38-foot graphite/epoxy cored nose cone for X-59 supersonic aircraft.

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Core

Revolutionizing space composites: A new era of satellite materials

A new approach for high volumes of small satellite structures uses low-CTE, low-cost CFRP cellular core, robust single-ply skins and modular panel systems to cut lead time, labor and cost for reflectors, solar arrays and more.

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Natural Fibers

ORGANIC project to 3D print bio-inspired structures with bio-based materials

EU-funded Horizon Europe project tackles lower production cost, enhanced sustainability and first-time-right parts fabrication through the fusion of biology, additive manufacturing and AI.

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CAMX

Foamed plastics are well suited for CFRP core applications

CAMX 2025: Sekisui Kasei USA presents ST-Eleveat RNW E foamed plastic and ST-Foamac rigid foam board products designed to support composite core needs.

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Carbon Fibers

Star Composites begins operations in Spartanburg

The start of carbon fiber multiaxial fabrics manufacturing, as well as relocation of Sky Advanced Materials, Marex and Carbon Core under the Star Composites brand, will further support customers.

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Glass Fibers

Hybrid composite architecture enables rigid wind propulsion solution for maritime decarbonization

GT Wings’ AirWing leverages aerospace engineering principles combined with hybrid glass and carbon fiber composite construction to deliver up to 30% fuel savings through compact, deck-compatible wind propulsion.

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Knowledge Centers

Composites in Advanced Air Mobility
Composites in Advanced Air Mobility

Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

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Automated Composites
Automated Composites

In the Automated Composites knowledge center, CGTech brings you vital information about all things automated composites, from the manufacturing processes to the vendors and necessary tools.

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Latest Core News And Updates

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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Core

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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Core

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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Core

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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Sustainability

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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Marine

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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Featured Posts

Application

Infused sandwich window frame components help double-decker buses meet weight targets

Prototype GFRP parts were evaluated by Spanish bus manufacturer Carrocerías Ayats as an initial move toward lighter, more efficient, more automated parts and processes.

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Feature

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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Core

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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