Foam Cored Carbon Fibre Panel

It's not possible to give an exact weight because it would depend on many things (how the sheet is supported, what the span in, how the weight it loaded, whether the sheet is a 'free span' (i.e. not bonded/fixed) or bonded or fixed (so you get a 'drum skin' effect). That said, you could be confident that a sheet slid over a hole such that the sheet is supported on all sides would support the weight of an average person quite easily.

The foam used in this sheet is our EasyCell 75, for which the datasheet is readily available here: EasyCell 75. The properties for the carbon fibre and glass used in the sheet we don't currently have data for but we are having mechanical property testing done on the finished foam core panel for which the data should be available soon.

What’s the intended final use of the panel?... If it's something along the lines of a splitter then you can add rubber trim around the leading edge, this is easy to do, will leave a neat finish and protect the vulnerable foam of the panel.

If you really want to extend the same woven carbon fibre finish around the edge of the panel then this would be incredibly difficult and pretty much the only way to do it would be to make a moulded part, i.e. start with a mould and then laminate a new part where the carbon fabric followed the contour of the moulded lip. A more realistic ‘half-way’ option would be to fill the edge with a carbon filler; this can look very neat, matches the colour of the carbon fabric, and will provide strength and protection for the exposed edge. To do this, you would remove about 3mm of the foam core, all the way around, and then use a product like our Black Epoxy Repair Filler to fill the 3mm gap. Once it’s cured, you can flat and polish it to a high quality finish.

Each skin on both the 6mm and 11mm panels, is approximately 0.5mm thick

The maximum working temperature for this sheet is 70C.

The Foam core panel is fractionally stiffer than the 3mm resin infused sheet. It is also significantly lighter in weight and easier to cut. However, the 3mm resin infused sheet, being solid laminate, is much tougher and impact resistant than the foam cored panel.

Water jet cutting will cut the foam core panel easily and quickly. As with most composites, adjustment of the water jet settings may be necessary for the cut to remain clean and not chip or delaminate the edge of the sheet.

For example, I want to route out one skin and bend the other to create a 90deg bend. Also because the main loading will be shear I intend to cut out my parts at 45deg to the panel edges.

No, not around a 90 degree bend. The problem would be the carbon sheet on the outer skin which would not be able to be bent around a 90 degree (or even 45 degree) corner without having a significant radius. If the bend was around a tight radius then the sheet is likely to fracture.