For years, genuine Nomex® aramid paper 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 ultra-lightweight ‘Aerospace Grade’ Nomex® weighs just 29kg/m³ and is much sought-after by competition R/C aero modellers and motorsport teams as one of the lightest core materials on the market. Targeted specifically at the competition R/C and motorsport market we stock this grade of honeycomb in 2mm Nomex® and 3mm Nomex® thicknesses.
We also stock a higher density Commercial Grade Nomex® honeycomb in 5mm and 10mm thicknesses for a wider range of 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, 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.
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