Railway Applications — Aluminium Honeycomb Solutions

Optimised aluminium honeycomb structures delivering lightweight performance and durability for railway applications.

High-performance structures for the rail industry

Halcyon designs and supplies aluminium honeycomb sandwich panels specifically adapted to the requirements of railway rolling stock. Our solutions meet the demands for lightweight design, rigidity, durability and maintainability expected by manufacturers, system suppliers and integrators in the railway sector.

By mastering materials and manufacturing processes, our panels can be integrated both into secondary structures and on-board equipment, even in severe operating environments.

A solution engineered for demanding environment

Halcyon’s aluminium honeycomb structures combine lightweight performance with high mechanical strength. They are designed to address the specific challenges of the rail sector, including vibration and impact resistance, fatigue performance and fire/smoke requirements.

Our solutions help to:

⇒ Significantly reduce structural mass

⇒ Improve mechanical and vibration performance

⇒ Increase equipment service life

⇒ Intégrer des fonctions complexes dès la conception (inserts, fixations, usinage…)

Lightening, strengthening, optimising — a single solution for multiple railway functions.

Thanks to Halcyon technology, our sandwich panels are used throughout rolling stock:

🔷 Partitions and walls

🔷 Lightweight floors & ceilings

🔷 Interior fit-out modules

🔷 Seat structures

🔷 Structural assemblies

🔷 Technical parts with complex 2D & 3D geometries

This versatility contributes to reducing overall vehicle mass while ensuring rigidity, durability and ease of integration in demanding railway environments.

Applications ferroviaire sandwich nid d'abeille aluminium

End-to-end technical support

At Halcyon, we support our railway customers at every stage of the project. From initial design to series production, we provide continuous support including design engineering, prototyping and final validation. This integrated approach enables us to deliver aluminium honeycomb solutions that are reliable, optimised and tailored to the specific needs of rolling stock applications.

Design office

Methods office

Tooling

Prototyping

Production

Control

Example — Passenger Seat Back

This passenger seat back illustrates Halcyon’s ability to design optimised structures using aluminium honeycomb technology for demanding rail applications.

The part is a monobloc design that integrates both structural and aesthetic functions, simplifying assembly, reducing the number of components and facilitating integration into the rail environment.

Thanks to the sandwich structure with aluminium honeycomb core, the mass of the part is reduced by approximately 45 % compared to traditional solutions, while maintaining the required mechanical performance.

In addition, the materials used are fully recyclable, contributing to sustainable design aligned with environmental priorities in the rail industry.