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
ELFOAM rigid foam products

Latest Core Articles

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Automotive

Fibryx highlights cost-competitive natural fiber sandwich panels

Under partnerships with suppliers like Biofibix, the University of Stuttgart spin-off is supporting lightweight construction in mobility with lightweight, sustainably sourced composite offerings.

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Marine

Gurit expands U.S. Corecell operations to support subsea demand

Corecell structural foam core production is being expanded in Dallas, Texas, and will be operational by Q3 2026.

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JEC

Mel Composites announces expansion plans, highlights custom core kitting and foam engineering

JEC World 2026: Precision core kits designed to remove complexity and Evonik foam solutions cut production time and improve composites performance.   

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Trends

Gurit becomes core kit design partner for leading wind turbine OEM

Five-year supply agreement for Opticore kits through Gurit will streamline the OEM’s process, reduce complexity and unify final designs.

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ATL/AFP

IFW realizes complex composite sandwich structures with AFP

SHOREliner project demonstrates automated manufacture of topology-optimized aircraft fuselage structures showcasing digital process chain.

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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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Hydraulic & Pneumatic Presses
precision-engineered heating solutions
Industrial CNC Routers
Greenerd Compression Molding
precision-engineered heating solutions

Latest Core News And Updates

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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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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Natural Fibers

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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CAMX

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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Turn-Key Pultrusion Systems
Thermwood LSAM Elevate Precision Beyond Scale
ACR 4 Hot Bonder
AFP, Slitting, Filament Winding, Automation
CAMX 2026

Featured Posts

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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Space

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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Infusion

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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Prepregs

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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ACMA's Thermoplastic Composites Conference
JEC World 2026
CONTRAX
Alpha Technologies' ESR polymer testing instrument
Visit Exel Composites at JEC World 2026