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Diab (DeSoto, Texas, U.S. and Laholm Sweden) has developed a new recyclable 100% thermoplastic sandwich panel for aerospace cabin interiors. The thermoplastic sandwich is designed to be a solution to current challenges such as sustainability, REACH compliance and a circular economy.

The solution combines the advantages of Diab’s structural foam core Divinycell F and thermoplastic skins. The materials used have been tested and qualified by aerospace OEMs, and are fully compliant with all industry requirements.

Diab’s sandwich panels for aerospace cabin interiors are made with a custom manufacturing process, including the skins,core bonds and shaping. This can also include decorative skins. Cabin interior panels are produced in a single-step process that yields 30-80% higher mechanical properties and fire resistance behavior than current honeycomb core and phenolic resin solutions, according to the company. The process also decreases weight by up to 10%, reduces production cycle time and reduces production costs by 20%.

Divinycell F is a 100% thermoplastic Divinycell F core material that is already REACH-compliant. It is said to be recyclable and has a zero-waste production process. A sandwich core for commercial aircraft interiors, it is FST-compliant, has low sensitivity to water absorption, optimizes surface finish and reduces labor times. Another focus is its sustainability, which it offers through use of a recycled core.

Diab says it has demonstrated the recyclability of the panel with a process consisting in grinding the panel, then extruding recycled pellets and finally injection molding into 3D parts. Other recycling scenarios are said to be possible.