Lightweight CompositePanel Solutions
PP honeycomb sandwich panels with 15+ face sheet options, FRP panels, CFRT thermoplastic composites, and PET foam core materials. One-stop lightweight panel solutions for RV, bus, truck, marine, and construction industries. The professional plywood replacement.
Advanced Composite Panel Solutions
From PP honeycomb sandwich panels to CFRT thermoplastic sheets, we engineer lightweight composite solutions with precise material selection for every application.
PP Honeycomb Sandwich Panels
Polypropylene honeycomb core laminated with 15+ face sheet options including FRP, CFRT, aluminum, non-woven fabric (PET/PP, 60-200g/m²), automotive carpet/felt, vinyl leather (PVC with wood grain patterns), carbon fiber (3K twill), ACP, stainless steel, HPL, rubber, cork, and more. Composite methods include thermal lamination, adhesive bonding, and film lamination.
FRP Composite Panels
Glass fiber reinforced plastic (25-40% fiber content) with polyester, vinyl ester, or epoxy resin matrix. Available as standalone sheets (0.7-5.0mm) or laminated onto PP honeycomb, PET foam, PU foam, or XPS foam cores. Surface options include gel-coat (glossy/matte/embossed), painted, and textured finishes.
CFRT Thermoplastic Sheets
Continuous fiber reinforced thermoplastic sheets with 2-9 UD tape layers. Fiber options: glass fiber or carbon fiber. Resin matrix: PP, PE, PA, PC, PBT, PEI, PEEK, PPS. 3-5× higher tensile strength than chopped fiber FRP at same thickness. 100% recyclable thermoplastic construction with superior scratch and impact resistance.
Automotive Interior Parts
OEM-grade sun visors, trunk load floors, parcel shelves, headliners, and door panels. PP honeycomb core with automotive carpet/felt, non-woven fabric, or leather face sheets. 26 years of expertise supplying Geely, Chery, EXEED, Zeekr, and more. IATF 16949 certified production with 300+ patents.
PET Foam Core Materials
Closed-cell PET foam core available in 6 density grades (80-260 kg/m³). Compressive strength ranges from 0.85 to 5.20 MPa. 100% recyclable, thermoformable for complex shapes, compatible with all resin systems. Temperature resistance up to 100°C long-term, 150°C short-term. Ideal structural core for FRP and CFRT sandwich panels.
Face Sheet Selection Guide
Choose the right face sheet (skin) material for your PP honeycomb or foam core sandwich panel. Each option offers unique properties optimized for specific applications.
| Face Sheet Material | Thickness | Key Features | Best Applications | Surface Finish |
|---|---|---|---|---|
| FRP / GRP | 0.7-5.0mm | Waterproof, UV resistant, high flexural strength | RV walls/roof, reefer trucks, clean rooms | Glossy / Matte / Embossed |
| CFRT Sheet | 0.7-10mm | 3-5× stronger than FRP, scratch resistant, recyclable | EV battery shields, truck walls, marine hulls | Smooth / Anti-slip embossed |
| Aluminum Sheet | 0.3-1.5mm | Structural rigidity, thermal conductivity, lightweight | Facade cladding, solar panels, industrial flooring | Mill / Anodized / Painted |
| Checkered Aluminum | 0.8-2.0mm | Anti-slip pattern, corrosion resistant, heavy-duty | Bus floors, truck cargo floors, industrial walkways | Diamond / 5-bar pattern |
| Non-woven Fabric | 60-200 g/m² | Soft, breathable, excellent bonding substrate | Automotive headliners, insulation layers, packaging | PET / PP fiber |
| Automotive Carpet | 2-6mm | Needle-punched, multiple colors, acoustic insulation | Trunk floors, parcel shelves, door panels, headliners | Tufted / Needle-punch |
| Vinyl Leather (PVC) | 0.5-2.0mm | Easy-clean, decorative, moisture resistant | RV interior walls, furniture, marine interiors | Wood grain / Solid color / Custom |
| HPL (Laminate) | 0.6-1.2mm | Scratch resistant, decorative, fire retardant | Partition walls, raised floors, furniture, displays | Wood / Stone / Solid |
| Carbon Fiber | 0.3-2.0mm | Ultra-high strength-to-weight, premium aesthetic | Motorsport, aerospace, luxury interiors | 3K twill weave |
| Stainless Steel | 0.3-1.0mm | Hygienic, corrosion resistant, high temperature | Food processing, medical, chemical environments | Brushed / Mirror / #4 |
| Rubber Sheet | 1-5mm | Anti-slip, vibration damping, impact absorption | Bus floors, gym flooring, industrial walkways | Coin / Diamond / Smooth |
| Cork | 1-6mm | Acoustic insulation, eco-friendly, warm touch | Flooring underlayment, wall panels, bulletin boards | Natural / Stained |
Custom face sheet combinations available. Contact our engineering team for material recommendations tailored to your specific requirements.
View Full Product Specifications
Precision-Engineered
Honeycomb Structure
Our PP honeycomb core utilizes precision-extruded tubular cell architecture for maximum structural efficiency. Each cylindrical cell distributes load evenly, creating panels that are remarkably light yet incredibly strong. The closed-cell structure ensures near-zero water absorption and excellent thermal/acoustic insulation.
Diverse Panel Solutions for Every Need
From white gel-coat FRP to black anti-slip CFRT, we manufacture panels in a wide variety of face materials, colors, textures, and specifications.
FRP Gel-Coat White
CNC Routed Panel
FRP Dark Finish
Sample Display Rack
CFRT Surface
CFRT Panel Stack
Trusted Across Industries
Each application requires a specific combination of core material and face sheet. Below are our recommended panel configurations for major industries.
Which Panel for Your Application?
Not sure which composite panel system is right for your project? Use our application-panel matching guide to find the optimal combination of core material and face sheet for your specific use case.
| Application | Recommended Panel | Core | Face Sheet | Why This Combination |
|---|---|---|---|---|
| RV / Motorhome Floor | PP Honeycomb + Anti-slip FRP | PP Honeycomb | FRP / CFRT | 50-70% lighter than plywood, 100% waterproof, CNC-routable |
| RV Sidewall & Roof | FRP + PU/XPS Foam | PU / XPS Foam | FRP (gel-coat) | Thermal insulation + weather resistance + UV protection |
| RV Interior Wall | PP Honeycomb + Vinyl/HPL | PP Honeycomb | Vinyl / HPL | Lightweight, decorative, easy-clean, moisture-proof |
| Bus / Coach Floor | PP Honeycomb + Rubber/Alu | PP Honeycomb | Rubber / Check Alu | Heavy-duty anti-slip, waterproof, formaldehyde-free |
| Truck Cargo Floor | CFRT + PET Foam | PET Foam | CFRT | High load-bearing, scratch resistant, lightweight |
| Reefer Truck Wall | FRP + PU Foam (80-100mm) | PU Foam | FRP | Best R-value 6.5/inch, seamless hygienic interior |
| EV Battery Shield | CFRT Multi-layer Sheet | N/A (solid) | CFRT | 120-300J impact, flame retardant, recyclable |
| Sun Visor / Headliner | PP Honeycomb + Fabric | PP Honeycomb | Carpet / Non-woven | Ultra-lightweight, formable, acoustic insulation |
| Marine Deck | PP Honeycomb + Anti-slip | PP Honeycomb | Anti-slip FRP | Corrosion-resistant, lightweight, no rot |
| Clean Room Wall | FRP + PET Foam | PET Foam | FRP (smooth) | Non-porous, hygienic, fire-rated, easy-clean |
CNC Custom Machining
& Precision Cutting
Beyond standard panel supply, we offer comprehensive CNC machining services to deliver ready-to-install composite components. Our advanced CNC routers and 5-axis cutting machines process panels into any shape, size, or contour according to your engineering drawings.
- Custom CNC routing, drilling, and edge profiling
- 5-axis machining for complex 3D contours
- Precision tolerance: ±0.5mm on all dimensions
- Support DXF, DWG, STEP, and PDF drawing formats
- Batch production from prototype to 10,000+ units
- Integrated edge banding and surface finishing
More Applications
Our composite panels serve far more industries than you might expect. Each application uses a specific panel configuration optimized for its unique requirements.
Bus & Coach Flooring
PP honeycomb + anti-slip rubber or checkered aluminum. Formaldehyde-free plywood replacement for public transit. Lightweight, waterproof, and fire-retardant.
Packaging & Flight Cases
PP honeycomb + FRP or ACP face sheets. Ultra-lightweight, impact-resistant panels for reusable transport cases and protective packaging.
Prefab Bathrooms
PP honeycomb + FRP surface. 100% waterproof, mold-proof composite wall and ceiling panels for modular bathroom pods.
Clean Rooms
FRP + PET foam or PP honeycomb + FRP. Smooth, non-porous, hygienic panels for pharmaceutical and electronics clean rooms.
Furniture & Display
PP honeycomb + plywood veneer or HPL. Ultra-light boards for exhibition stands, retail displays, and modern furniture.
Solar & New Energy
PP honeycomb + aluminum or FRP face sheets. Structural backing panels for photovoltaic arrays and energy storage enclosures.
Core Material Comparison
Choosing the right core material is critical to panel performance. Compare the key properties of PP honeycomb, PET foam, XPS foam, and PU foam to find the optimal solution for your application.
| Core Material | Density (kg/m\u00B3) | Compress. (MPa) | Thermal (W/m\u00B7K) | R-Value/inch | Max Temp | Recyclable | Best For |
|---|---|---|---|---|---|---|---|
| PP Honeycomb | 60-140 | 1.2-1.9 | N/A | Low | 80\u00B0C | Yes (PP) | Lightweight floors, walls, furniture, automotive |
| PET Foam | 80-260 | 0.85-5.2 | 0.032-0.038 | ~4.0 | 100\u00B0C | Yes (PET) | Structural panels, marine, aerospace |
| XPS Foam | 30-50 | 0.3-0.7 | 0.025-0.035 | ~5.0 | 75\u00B0C | Limited | Insulated walls, roofing, cold storage |
| PU Foam | 28-50 | 0.15-0.35 | 0.023-0.025 | ~6.5 | 80-100\u00B0C | No | Reefer trucks, cold rooms, high-insulation |
PP Honeycomb vs Traditional Materials
See how PP honeycomb composite panels outperform plywood, steel, and aluminum across key performance metrics.
| Property | PP Honeycomb Panel | Plywood | Steel | Aluminum |
|---|---|---|---|---|
| Weight (kg/m², 10mm) | 1.5-3.0 | 6.5-7.5 | 78.5 | 27.0 |
| Water Absorption | ≈0% | 15-25% | 0% | 0% |
| Compressive Strength | 1.2-1.9 MPa | 3-5 MPa | 250+ MPa | 70+ MPa |
| Corrosion Resistance | Excellent | Poor | Poor | Good |
| Thermal Insulation | Excellent | Moderate | Very Poor | Poor |
| Recyclability | 100% | Limited | Yes | Yes |
| Service Life | 15+ years | 3-5 years | 10+ years | 15+ years |
| CNC Machinability | Excellent | Good | Difficult | Good |
| Formaldehyde | Zero | Contains | Zero | Zero |
| Cost Efficiency | High | Moderate | Low | Moderate |
Quality Testing
Every panel undergoes rigorous testing per ISO and ASTM standards. Watch real tests from our quality lab demonstrating exceptional bonding strength and compressive performance.
Peeling Strength Test (ASTM D1781)
Demonstrates the bonding strength between face sheets and honeycomb core. Our panels consistently exceed industry standards for delamination resistance, ensuring long-term structural integrity in demanding applications such as RV floors and truck body panels.
Compression Strength Test (ASTM C365)
Shows the compressive strength of PP honeycomb panels under load. The tubular cell architecture distributes force evenly, achieving 1.24-1.89 MPa compressive strength (varies by cell size and density) while maintaining ultra-lightweight properties.
Real-World Applications
See how our composite panels are transforming industries with lightweight, durable, and sustainable solutions.
RV & Motorhome Floor Panels
PP honeycomb + anti-slip FRP face sheets are the preferred choice for leading RV manufacturers worldwide. At 10mm thickness, our panels weigh only 1.5-3.0 kg/m\u00B2 compared to 6.5-7.5 kg/m\u00B2 for plywood \u2014 a 50-70% weight reduction with 100% waterproof performance and zero formaldehyde.
- Floor: PP honeycomb + anti-slip FRP/CFRT
- Sidewall: FRP + PU/XPS foam for insulation
- Interior: PP honeycomb + vinyl/HPL for decoration
- Bathroom: PP honeycomb + FRP (100% waterproof)
- Furniture: PP honeycomb + plywood veneer
Truck, Trailer & Cold Chain
From dry freight truck floors to temperature-controlled reefer units, our panels deliver exceptional performance. Reefer walls use FRP + PU foam (80-100mm) for R-value 6.5/inch. Cargo floors use CFRT + PET foam for load-bearing strength. Hygienic, easy-clean interior surfaces.
- Reefer wall: FRP + PU foam, R-value 6.5/inch
- Cargo floor: CFRT + PET foam, high load-bearing
- Thermal conductivity: 0.023-0.025 W/m·K
- Hygienic seamless interior, easy to clean
Automotive & Electric Vehicles
CFRT multi-layer sheets for EV battery enclosure shields (120-300J impact resistance, flame retardant). PP honeycomb + automotive carpet/felt for sun visors, trunk load floors, parcel shelves, and headliners. 26 years of OEM expertise supplying Geely, Chery, EXEED, Zeekr.
- EV battery shield: CFRT multi-layer (120-300J)
- Sun visor: PP honeycomb + automotive fabric
- Trunk floor: PP honeycomb + carpet (lightweight)
- Headliner: PP honeycomb + non-woven (acoustic)
The Tower Advantage
Ultra Lightweight
Up to 70% lighter than traditional materials. PP honeycomb panel at 10mm weighs only 1.5-3.0 kg/m² vs plywood at 6.5-7.5 kg/m².
High Strength
Compressive strength 1.2-1.9 MPa (PP honeycomb core). CFRT flexural strength >420 MPa. Impact resistance up to 300J drop weight.
Eco-Friendly
100% recyclable PP and PET materials. Zero VOC emissions. PET foam can be recycled into new PET foam. Environmentally responsible manufacturing.
Certified Quality
ISO 9001, IATF 16949 certified. ASTM E84 fire rating. CE marking. Trusted by Toyota, VW, Geely, and leading OEMs.
State-of-the-Art Production Facilities
Our manufacturing network spans multiple facilities across China, equipped with advanced automated production lines, precision CNC routing, and comprehensive quality testing systems.
CNC Panel Cutting
Surface Coating Line
CNC Precision Routing
Precision Cutting
Sandwich Panel Line
Fiber Reinforcement
Automotive Parts Line
Lamination Process
Material Warehouse
Finished Panel Products
Panel Quality Inspection
Cold Chain Panel Production
Worldwide Shipping from Ningbo Port
Strategically located near Ningbo-Zhoushan Port \u2014 the world's busiest cargo port \u2014 we offer competitive shipping to North America, Europe, Southeast Asia, Middle East, and beyond. Our standard panel dimensions (2300\u00D71150mm) are optimized for efficient 20ft/40ft container loading.
Technical & Commercial FAQ
Find detailed answers about our composite panel products, material selection, technical specifications, and ordering process.
Ready to Transform Your Products?
Contact our engineering team to discuss your composite panel requirements. We provide custom solutions with the right core material and face sheet combination for your application.