TECHNOLOGY
Learn more about sandwich panel technology and Halcyon’s expertise in this area.
What is a Sandwich Panel?
A sandwich panel is a multi-layer composite material designed to provide an optimal balance between lightness and mechanical performance. It consists of two thin, strong outer skins bonded on either side of a lightweight but thick core. This configuration creates a structure that is both stiff, strong, and extremely lightweight.
The Skins
The skins of the sandwich panel provide mechanical strength in both tension and compression. The material of the skins is selected based on the required performance characteristics.
At Halcyon, we primarily use aluminum for the skins—a material that offers an excellent strength-to-weight ratio, good corrosion resistance, and high formability. This choice ensures both mechanical performance and lightness while being fully compatible with our aluminum honeycomb core.
The Core
Situated between the two skins, the core of the sandwich panel plays a crucial role in the overall performance of the structure. It can be either solid or hollow, as is the case with honeycomb structures. Its main function is to maintain a constant separation between the skins and to transfer mechanical loads through shear. By increasing the moment of inertia, it significantly enhances the panel’s stiffness while keeping the weight very low.
At Halcyon, we have mastered the use of aluminum honeycomb cores, a solution that is lightweight, strong, and perfectly suited to the most demanding technical applications.
Adhesives: The Invisible but Essential Bond
The performance of a sandwich panel largely depends on the quality of the bonding between its components. High-performance structural adhesives are used to bond the skins to the core, ensuring uniform load transfer and long-term durability. These adhesives must offer excellent shear and peel strength while being able to withstand demanding environments. At Halcyon, we carefully select and apply the most suitable adhesives for each application, playing a key role in the integrity and functionality of our panels.
Integrated Features
Beyond its mechanical properties, a sandwich panel can be designed to meet other functional requirements, such as energy absorption in case of impact, or thermal insulation. The choice of skin and core materials allows for an “integrated” approach that combines structural performance with specific features tailored to the project specifications.
Halcyon Innovation: Enabling Complex Shapes
At Halcyon, we push the boundaries of sandwich panels through a unique patented technology. Our innovation allows for the manufacture of aluminum honeycomb sandwich panels in complex shapes, without compromising on mechanical performance or lightness. This advancement opens up new possibilities in demanding sectors such as aerospace, defense, and transportation, where the combination of unconventional geometries, high rigidity, and low weight is crucial.
This exclusive process enhances our ability to meet ambitious specifications by offering tailor-made solutions that combine functionality, performance, and innovation.