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Safety Datasheet (SDS)170 KB

Specification

Product Data
Thickness10mm
ColourOrange
Weight and Dimensions
Length600mm
Width600mm
Wall Thickness0.11mm
Mechanical Properties
Compressive Strength (Stabilised)2.4MPa
Plate Shear Strength (lengthways)1.2MPa
Plate Shear Modulus (lengthways)40MPa
Plate Shear Strength (widthways)0.7MPa
Plate Shear Modulus (widthways)25MPa
Compressive Modulus (stabilised)140MPa
General Properties
Gross Weight0.1875kg

Shipping Information

This product listed to by in a range of sizes. One or more larger sizes are classed as 'oversize' for delivery to some international destinations which means that delivery might not be available to some countries or when combined with certain types of product (dangerous goods for example).

When checking the delivery cost of your order, if you receive an 'oversize' warning then you may need to select a smaller size of this product in order to continue. Alternatively, please contact us to discuss.

4.8mm Cell 48kg Nomex Honeycomb

Genuine commercial grade Nomex® aramid paper honeycomb core material. This low density, high compressive strength core material weighs just 48kg/m³ and is used as a core material in lightweight sandwich panels and moulded components. This commercial grade honeycomb has 4.8mm size cells and is very popular for use in motorsport, marine and recreational equipment applications. Nomex honeycomb can be incorporated into a structure in a number of ways including wet-lay, vacuum bagging, adhesive bonding and prepreg (with or without adhesive film).

Available in 5mm and 10mm thickness in a range of sheet sizes.


PRODUCT VERSIONS

Sheet Size
Thickness

AVAILABILITY:More than 10 availablefor immediate shipping


PRICE
£39.86inc. VAT
More than 10 availablefor immediate shipping
QTY
SHEETS
SHEETS
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For years, genuine Nomex® aramid honeycomb has been the de-facto standard in none-metallic, lightweight core materials for sandwich composites. Nomex® honeycomb is used extensively in aerospace applications like cabinets, lockers and bulkheads as well as in high-performance motorsports including Formula 1 and WRC.

Genuine Nomex® is known for its excellent mechanical properties and trusted, consistent manufacturing precision. This lightweight yet very strong Commercial grade Nomex® weighs just 48kg/m³ making it considerably lighter than many alternative core materials (such as closed cell PVC foam). We have selected the 48kg/m³ with a 4.8mm cell size because of its ideal suitability for a wide range of applications where its combination of small cell size and sturdier wall thickness make it easy to handle, use and bond-to. The strength and performance of this specification makes it perfect for motorsport and other high performance applications (such as splitters, under-trays, bulk-heads etc.) that also need to be real world strong.

Our 4.8mm/48kg/m³ Nomex® honeycomb is stocked in 5mm Nomex® and 10mm Nomex® thicknesses, specifically selected as ideal core thicknesses for motorsport and marine applications.

We also stock a lower density Aerospace Grade Nomex® honeycomb in 2mm and 3mm thicknesses for the specialist requirements of some aerospace, UAV and competition R/C aero-modelling uses.

Nomex® honeycomb is supplied expanded and ready to use, as pictured.

Further Information

How to Use

Nomex® honeycomb is suitable for use as a structural core material in advanced composites ‘sandwich’ panels and laminates. At the 2mm and 3mm thicknesses listed on this page the honeycomb is capable of conforming around reasonable contoured mould surfaces or can, of course, be used for completely flat panels.

Use with Prepregs

Nomex® honeycomb is commonly used sandwiched between outer skins of prepreg carbon fibre to result in an incredibly lightweight, yet stiff sandwich panel.

Lamination in this way can be achieved with or without the need for a resin film adhesive (depending on the ratio and bond characteristics of the resin system used in the prepreg). Curing of the inner and outer skins, along with the adhesive film (such as our XPREG® XA120 Prepreg Adhesive Film, can be done all at the same time or in multiple stages; for example curing inner and outer skins then bonding the skins to the core. The simplest method is a ‘one-shot’ cure where the resin flow of the curing prepreg also acts as the resin to bond the reinforcement to the core.

Use with Hand Layup / Vacuum Bag

Although Nomex® is known for its suitability for use with prepreg laminates, it can also be used, with excellent results, in more simple hand layup or vacuum bagged processing.

The simplest way to create a very lightweight Nomex® honeycomb panel would be to laminate a composite sheet using glass or carbon fibre with epoxy resin to form the outer skins for the panel. Using a peel-ply on the open surface of the laminate will make preparation for bonding much easier. Once cured the sheet can be removed from the laminating surface (typically a sheet of glass), ready to be sandwiched either side of the honeycomb. A batch of epoxy resin can be mixed and spread onto a surface so that the honeycomb can be dipped into it, coating the contact areas with resin without resulting in un-needed resin in none-contact areas. The honeycomb can then be placed onto the composite sheet and the first side allowed to cure. Once cured, repeat the process by dipping the other side of the honeycomb into resin and weighting it down onto the other skin.

Resin Infusion

The open cell structure of Nomex (much like aluminium honeycomb) means that it is not suitable for resin infusion. If a laminate containing Nomex was infused the cells of the Nomex honeycomb would simply fill with resin.

If you do wish to make use of Nomex honeycomb along with resin infused laminates then the laminates ‘skins’ must be infused first and then bonded to the Nomex core in a second stage.

For years, genuine Nomex® aramid honeycomb has been the de-facto standard in none-metallic, lightweight core materials for sandwich composites. Nomex® honeycomb is used extensively in aerospace applications like cabinets, lockers and bulkheads as well as in high-performance motorsports including Formula 1 and WRC.

Genuine Nomex® is known for its excellent mechanical properties and trusted, consistent manufacturing precision. This lightweight yet very strong Commercial grade Nomex® weighs just 48kg/m³ making it considerably lighter than many alternative core materials (such as closed cell PVC foam). We have selected the 48kg/m³ with a 4.8mm cell size because of its ideal suitability for a wide range of applications where its combination of small cell size and sturdier wall thickness make it easy to handle, use and bond-to. The strength and performance of this specification makes it perfect for motorsport and other high performance applications (such as splitters, under-trays, bulk-heads etc.) that also need to be real world strong.

Our 4.8mm/48kg/m³ Nomex® honeycomb is stocked in 5mm Nomex® and 10mm Nomex® thicknesses, specifically selected as ideal core thicknesses for motorsport and marine applications.

We also stock a lower density Aerospace Grade Nomex® honeycomb in 2mm and 3mm thicknesses for the specialist requirements of some aerospace, UAV and competition R/C aero-modelling uses.

Nomex® honeycomb is supplied expanded and ready to use, as pictured.

Further Information

How to Use

Nomex® honeycomb is suitable for use as a structural core material in advanced composites ‘sandwich’ panels and laminates. At the 2mm and 3mm thicknesses listed on this page the honeycomb is capable of conforming around reasonable contoured mould surfaces or can, of course, be used for completely flat panels.

Use with Prepregs

Nomex® honeycomb is commonly used sandwiched between outer skins of prepreg carbon fibre to result in an incredibly lightweight, yet stiff sandwich panel.

Lamination in this way can be achieved with or without the need for a resin film adhesive (depending on the ratio and bond characteristics of the resin system used in the prepreg). Curing of the inner and outer skins, along with the adhesive film (such as our XPREG® XA120 Prepreg Adhesive Film, can be done all at the same time or in multiple stages; for example curing inner and outer skins then bonding the skins to the core. The simplest method is a ‘one-shot’ cure where the resin flow of the curing prepreg also acts as the resin to bond the reinforcement to the core.

Use with Hand Layup / Vacuum Bag

Although Nomex® is known for its suitability for use with prepreg laminates, it can also be used, with excellent results, in more simple hand layup or vacuum bagged processing.

The simplest way to create a very lightweight Nomex® honeycomb panel would be to laminate a composite sheet using glass or carbon fibre with epoxy resin to form the outer skins for the panel. Using a peel-ply on the open surface of the laminate will make preparation for bonding much easier. Once cured the sheet can be removed from the laminating surface (typically a sheet of glass), ready to be sandwiched either side of the honeycomb. A batch of epoxy resin can be mixed and spread onto a surface so that the honeycomb can be dipped into it, coating the contact areas with resin without resulting in un-needed resin in none-contact areas. The honeycomb can then be placed onto the composite sheet and the first side allowed to cure. Once cured, repeat the process by dipping the other side of the honeycomb into resin and weighting it down onto the other skin.

Resin Infusion

The open cell structure of Nomex (much like aluminium honeycomb) means that it is not suitable for resin infusion. If a laminate containing Nomex was infused the cells of the Nomex honeycomb would simply fill with resin.

If you do wish to make use of Nomex honeycomb along with resin infused laminates then the laminates ‘skins’ must be infused first and then bonded to the Nomex core in a second stage.

Downloads (1)

Safety Datasheet (SDS)170 KB

Specification

Product Data
Thickness10mm
ColourOrange
Weight and Dimensions
Length600mm
Width600mm
Wall Thickness0.11mm
Mechanical Properties
Compressive Strength (Stabilised)2.4MPa
Plate Shear Strength (lengthways)1.2MPa
Plate Shear Modulus (lengthways)40MPa
Plate Shear Strength (widthways)0.7MPa
Plate Shear Modulus (widthways)25MPa
Compressive Modulus (stabilised)140MPa
General Properties
Gross Weight0.1875kg
Can’t find the answer you’re looking for?Ask our technical team a question.

Nomex has very good compressive strength. In therory there would be no problem using a carbon/Nomex sandwich panel for the type of applications you're suggesting although normally these particular products would generally be single outer skins. A gun stock for example is quite a thick profile and not a classic application for a honeycomb core.

You would just sandwich layers (of carbon fibre, class fibre, aluminium etc.) either side, leaving the honeycomb empty inside. This way the core remains very light giving you a very strong and light finished panel.

In industry, the most common method is a temperature-cured adhesive film, such as XA120, however these adhesive films require pressure and temperature, making them impractical for many users, furthermore, they are less suitable for ultra-light structures - themselves adding 200 or 300gsm to the laminate.

If you are unable to process film adhesives, then the method we recommend for best results is to dip the Nomex in liquid epoxy resin. The reason to do it this way is it limits the resin used to only where the Nomex will contact the sheet rather than the more wasteful method of skimming a layer of resin over the whole panel.

By dipping the Nomex into a resin bath, some resin will bond to the cell walls thus creating a meniscus when laid onto the sheet. This thin fillet of extra resin will help improve the bond strength by increasing the bond surface area.

We would recommend our EL2 Epoxy Laminating Resin for this purpose. Done correctly, we have been able to make very well bonded Nomex cored panels where the adhesive contributes less than 50gsm to the finished panel (per bond line) which is significantly lighter than using an adhesive film.

The Nomex Honeycomb can be cut in a number of different ways, however in our experience we would recommend 2 main methods that work well.

The first and most precise method is to cut the Honeycomb using a sharp Stanley type knife and metal ruler. The blade is used to cut the Nomex cell wall at a time, guided by the metal ruler to give a neat and accurate cut line.

The second method is to use large scissors or shears to quickly and easily cut through the sheet. This is especially useful for the thinner sheets and also where a large amount needs to be cut down. The scissors can cause a slight bit of tearing and crush on the very edge of the sheet so this method works best where the edge of the sheet is trimmed after manufacture.

Other techniques are possible and may well work. However it is key to remember to avoid distorting the cells too much and anything too aggressive may well tear and rip into the cell structure leaving a poor quality edge.

The aerospace grades in 2 and 3mm are more suited to knife cutting whereas the commercial grades are stiffer and so can be cut on a table saw or similar, if required.

Although Nomex Honeycomb naturally has a high level of fire resistance and is self-extinguishing, this specific material as stocked has not been formally certified to any level of fire resistance.

Yes the Nomex honeycomb can be bent around some reasonably tight radii in a single axis curve. It does have a tendency to try and bow in the opposite plane when bent around a tight curve, so it may need a little force to hold it in place while being bonded.

Yes, certainly. ET538 is a good choice for use with Nomex honeycomb and will bond and perform well with Nomex and carbon fibre (or other composite) skins.

Yes, for bigger panels you can butt join the sheets of Nomex Honeycomb to make a larger panel.

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Shipping Information

This product listed to by in a range of sizes. One or more larger sizes are classed as 'oversize' for delivery to some international destinations which means that delivery might not be available to some countries or when combined with certain types of product (dangerous goods for example).

When checking the delivery cost of your order, if you receive an 'oversize' warning then you may need to select a smaller size of this product in order to continue. Alternatively, please contact us to discuss.

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