Core Materials for Composites

Composite core materials serve as the central structural component in composite structures, providing stability, strength, and support while often contributing to the overall lightweight nature of the final product. These cores, typically made of materials like foam, honeycomb structures, or balsa wood, are sandwiched between layers of composite skins to form a composite panel. Their inherent properties—such as high strength-to-weight ratios, excellent insulation, and impact resistance—make them integral in various industries, including marine, aerospace, and construction, where weight reduction and structural integrity are paramount. The choice of core material plays a crucial role in determining the performance and characteristics of the composite structure.

Post Cure: Composite seaglider craft redefine coastal transportation operations
Core

Post Cure: Composite seaglider craft redefine coastal transportation operations

The Viceroy all-electric flagship seaglider being developed by REGENT Craft in Rhode Island operates exclusively over water.  

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Toray Advanced Composites hi-temperature materials
Hydraulic & Pneumatic Presses

Latest Core Articles

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Core

HRC supports Range Aviation’s LEU100 eVTOL in advancing future low-altitude logistics

HRC completed a composite design and manufacturing project with Range Aviation, supplying materials, engineering, manufacturing support and comprehensive compliance checks.

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Core

Gurit inaugurates Advanced Composites R&D Center in China

To be fully operational by end of 2025, the center will drive the development of novel composite technologies including PET, complementing Gurit’s existing global hubs.

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Infusion

Mel Composites materials, technical support enhances Aresa fishing vessel production efficiency

Mel delivered pre-processed structural components and engineering support for the four commercial vessels, reducing build time through workflow optimization and CNC-cut Aircell HR80 core integration.

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Aerospace

RWC composite radomes facilitate R4 Integration military search and rescue operations

Completed delivery of nine “no tooling” Ka-band and KaKu-band radomes are an extension of a previous program for a single proof-of-concept radome for C130 aircraft and similar platforms.

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Core

Gurit secures multiyear subsea contract for Corecell foam core

Long-term structural core supply, already backed by a long history of success, will diversify Gurit beyond its traditional markets.

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Aerospace

Cutting 100 pounds, certification time for the X-59 nose cone

Swift Engineering used HyperX software to remove 100 pounds from 38-foot graphite/epoxy cored nose cone for X-59 supersonic aircraft.

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Knowledge Centers

CW Tech Days: Sustainability
CW Tech Days: Sustainability

This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.

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CW Tech Days: Bonding and Welding
CW Tech Days: Bonding and Welding

Join us for insights into advanced bonding techniques and welding processes for composite materials to ensure durability and structural integrity.

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Sustainability
Sustainability

The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.

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ELFOAM rigid foam products
Airtech
advanced materials
JEC World 2026
ACR 4 Hot Bonder

Latest Core News And Updates

Sustainability

ORGANIC project to 3D print bio-inspired structures with bio-based materials

EU-funded Horizon Europe project tackles lower production cost, enhanced sustainability and first-time-right parts fabrication through the fusion of biology, additive manufacturing and AI.

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Carbon Fibers

Foamed plastics are well suited for CFRP core applications

CAMX 2025: Sekisui Kasei USA presents ST-Eleveat RNW E foamed plastic and ST-Foamac rigid foam board products designed to support composite core needs.

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Core

Star Composites begins operations in Spartanburg

The start of carbon fiber multiaxial fabrics manufacturing, as well as relocation of Sky Advanced Materials, Marex and Carbon Core under the Star Composites brand, will further support customers.

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Core

Airbus to design, build ESA ExoMars rover lander platform

The resurrected Rosalind Franklin composite rover mission’s key systems will be upgraded with support from the TAS, ESA and NASA for a planned launch in 2028.

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Defense

Norco delivers GFRP hard hulled riverine craft for BAE Systems

Norco’s broad-ranging materials and manufacturing expertise revitalize UK MOD legacy craft, providing a solution for future defense and communications sector projects.

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JEC

PVC foam core combines reliability with environmental sustainability

JEC World 2025: Maricell will have its own branded booth to present three new MYcell products targeting various sector requirements and sustainability initiatives.

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Composites One - distributor
Industrial CNC Routers
Alpha Technologies' ESR polymer testing instrument
PTXPO 26

Featured Posts

Wind/Energy

Revolutionizing space composites: A new era of satellite materials

A new approach for high volumes of small satellite structures uses low-CTE, low-cost CFRP cellular core, robust single-ply skins and modular panel systems to cut lead time, labor and cost for reflectors, solar arrays and more.

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Marine

Hybrid composite architecture enables rigid wind propulsion solution for maritime decarbonization

GT Wings’ AirWing leverages aerospace engineering principles combined with hybrid glass and carbon fiber composite construction to deliver up to 30% fuel savings through compact, deck-compatible wind propulsion.

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Core

Infused sandwich window frame components help double-decker buses meet weight targets

Prototype GFRP parts were evaluated by Spanish bus manufacturer Carrocerías Ayats as an initial move toward lighter, more efficient, more automated parts and processes.

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Filament Winding

Composites end markets: New space (2025)

Composite materials — with their unmatched strength-to-weight ratio, durability in extreme environments and design versatility — are at the heart of innovations in satellites, propulsion systems and lunar exploration vehicles, propelling the space economy toward a $1.8 trillion future.

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PUR composite sandwich panels for 3D automotive parts, high-volume panels and more

At its U.S. sites, Ascorium produces glass fiber/PUR 3D parts via semi-automated molding, high-volume flat panels via a continuous line while working toward bio-based PUR and recycling.

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Core

VIDEO: Precision fabrication of honeycomb materials

MachineTek showcases its precision fabrication of honeycomb materials at CAMX 2024.

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CONTRAX
ACR 4 Hot Bonder
UV Cured Powder Coatings for Carbon Fiber
Airtech 3D printing Solutions