Composite Solutions for Every Industry
From recreational vehicles to aerospace, our lightweight composite panels are engineered to meet the unique demands of diverse industries. Each application features a detailed component-to-panel matching guide with recommended core materials, face sheets, and technical specifications.
RV Floor Panels & Camper Van Manufacturing
Our lightweight composite RV floor panels and motorhome flooring are transforming the recreational vehicle industry. By replacing traditional plywood with PP honeycomb sandwich panels, RV manufacturers achieve 50–70% weight reduction while improving thermal insulation and durability. The closed-cell PP honeycomb core (density 60–140 kg/m³) provides excellent compressive strength (1.2–1.9 MPa) while maintaining near-zero water absorption — a critical advantage over plywood which swells, delaminates, and rots when exposed to moisture. Our camper floor panels are 100% waterproof, rot-proof, formaldehyde-free (E0 grade), and maintain structural integrity even after years of exposure to harsh weather conditions from −40°C to +80°C.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Floor | PP Honeycomb (10–12mm cell, 20–30mm thick) | Anti-slip vinyl leather or rubber surface | Lightweight, waterproof, load-bearing, easy to clean |
| Sidewall | FRP + PU Foam (40–60mm) | Gel-coat FRP exterior + HPL interior | Thermal insulation R-value 4.0+, weather resistant |
| Roof | FRP + XPS Foam (30–50mm) | Gel-coat FRP both sides | Lightweight, waterproof, good insulation |
| Interior Wall | PP Honeycomb (8mm cell, 10–15mm) | HPL or vinyl leather | Ultra-lightweight, decorative, easy to clean |
| Furniture Board | PP Honeycomb (8mm cell, 15–20mm) | Plywood veneer or HPL | 1/5 weight of MDF, excellent flatness |
| Bathroom Panel | PP Honeycomb (10mm cell, 15mm) | FRP both sides | 100% waterproof, mold-proof, smooth surface |
Available Panel Configurations
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Performance Highlights
Truck Floor Panels & Trailer Flooring
Commercial truck floor panels and trailer flooring manufacturers worldwide are adopting our composite sandwich panels to build lighter, more fuel-efficient vehicles. For dry cargo trucks and trailers, CFRT + PET foam or PP honeycomb panels provide the compressive strength needed for forklift traffic (5+ tons/m²) while reducing floor weight by 30–50% compared to traditional hardwood or steel. Our FRP honeycomb panels are also widely used as bus floor panels and coach flooring for public transit vehicles. The composite construction eliminates corrosion, rot, and warping issues that plague traditional plywood and steel truck floors, translating directly to increased payload capacity and reduced maintenance costs.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Cargo Floor | CFRT + PET Foam (Procore 150–200, 25–40mm) | Anti-slip rubber or checkered aluminum | High compressive strength for forklift traffic |
| Sidewall | CFRT + PET Foam (20–30mm) or FRP + Plywood | CFRT exterior, painted interior | Impact resistant, lightweight, durable |
| Roof Panel | CFRT + XPS Foam (20–30mm) | CFRT both sides | Lightweight, waterproof, UV resistant |
| Trailer Floor | PP Honeycomb (12mm cell, 30–50mm) | Checkered aluminum top + FRP bottom | Cost-effective, lightweight, anti-slip |
| Bus Floor | PP Honeycomb (10mm cell, 25–35mm) | Anti-slip rubber or vinyl surface | Waterproof, lightweight, formaldehyde-free |
Available Panel Configurations
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Performance Highlights
Cold Chain & Refrigerated Transport
Cold chain logistics demands panels that deliver exceptional thermal insulation while meeting strict food safety standards. Our FRP + PU foam insulated panels achieve R-values of 6.5 per inch — the highest thermal resistance available in composite sandwich construction. The closed-cell PU core (density 28–50 kg/m³) combined with smooth, non-porous FRP face sheets creates an impermeable barrier against moisture, bacteria, and temperature fluctuation. All panels feature smooth, non-porous surfaces that meet HACCP requirements for cold chain hygiene compliance. For refrigerated truck floors, we recommend CFRT + PET foam construction for superior load-bearing capacity combined with thermal insulation.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Wall Panel | FRP + PU Foam (80–100mm) | Gel-coat FRP both sides (white, smooth) | Best insulation R-value, hygienic food-grade surface |
| Floor Panel | CFRT + PET Foam (Procore 150, 30–40mm) | Anti-slip CFRT top + FRP bottom | Load-bearing for pallets + thermal insulation |
| Roof Panel | FRP + PU Foam (60–80mm) | Gel-coat FRP exterior + smooth FRP interior | Lightweight insulation, waterproof |
| Door Panel | FRP + PU Foam (80–100mm) + steel frame | FRP both sides with stainless steel threshold | Structural + insulation, hygienic threshold |
Available Panel Configurations
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Performance Highlights
Automotive Interior & EV Components
The automotive industry’s push toward electrification and lightweighting demands materials that reduce vehicle weight without compromising safety or NVH (noise, vibration, harshness) performance. Our PP honeycomb sandwich panels are the material of choice for interior trim components: headliners (with non-woven or automotive carpet face), trunk load floors (with needle-punched carpet), parcel shelves, door panels, and sun visor assemblies. For EV structural applications, our multi-layer CFRT (continuous fiber reinforced thermoplastic) sheets deliver impact resistance of 120J–300J for battery underbody shields and engine covers. With 26 years of sun visor manufacturing expertise and IATF 16949 certified quality, we are a trusted Tier 1/Tier 2 supplier to Geely, Chery, Zeekr, AITO, and other leading OEMs.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Headliner | PP Honeycomb (8mm cell, 5–8mm) | Non-woven fabric or automotive carpet | Ultra-lightweight, acoustic absorption, formable |
| Trunk Load Floor | PP Honeycomb (10mm cell, 10–15mm) | Needle-punched carpet top + non-woven bottom | Lightweight, load-bearing, cost-effective |
| Parcel Shelf | PP Honeycomb (8–10mm cell, 8–12mm) | Automotive carpet both sides | Lightweight, acoustic, supports 10–15 kg |
| Sun Visor | PP Honeycomb (8mm cell, 3–5mm) | Alcantara, fabric, or PU leather | Ultra-thin, lightweight, formable to shape |
| Door Panel Substrate | PP Honeycomb (8mm cell, 5–8mm) | Leather, fabric, or PVC film | Lightweight, NVH damping, decorative |
| EV Battery Shield | CFRT (3–9 layers, 2–6mm) | Glass fiber + PP matrix (no face sheet) | 120–300J impact, flame retardant, recyclable |
Available Panel Configurations
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Performance Highlights
Aviation & Aerospace
Aviation demands the ultimate in lightweight performance without compromising safety. Our advanced composite panels meet the stringent requirements of aircraft interior applications, including seat back panels, cabin partitions, overhead bin liners, galley structures, and lavatory walls. Every panel is engineered to meet FAR 25.853 flammability requirements and OSU 65/65 heat release criteria. The combination of Nomex or aluminum honeycomb cores with fire-retardant FRP or phenolic face sheets delivers an exceptional strength-to-weight ratio — typically 70% lighter than equivalent aluminum structures while maintaining full structural integrity under flight loads and pressure differentials.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Seat Back Panel | Nomex Honeycomb (3–6mm) | Phenolic FRP + decorative film | Ultra-lightweight, fire-rated, thin profile |
| Cabin Partition | Nomex Honeycomb (10–20mm) | Fire-retardant FRP both sides | Structural, fire barrier, acoustic |
| Overhead Bin Liner | Aluminum Honeycomb (6–10mm) | Phenolic FRP + decorative laminate | Impact resistant, fire-rated, lightweight |
| Galley Structure | Aluminum Honeycomb (15–25mm) | Phenolic FRP + stainless steel edge | Load-bearing, hygienic, fire-rated |
Available Panel Configurations
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Marine & Yacht Building
Marine environments present unique challenges: constant moisture exposure, salt spray, UV radiation, and dynamic wave loading. Our FRP honeycomb panels are engineered to thrive in these conditions, providing yacht and boat builders with lightweight, corrosion-proof materials that maintain structural integrity for 20+ years. For hull construction, FRP + PET foam (Procore 100–200) delivers the optimal balance of stiffness, impact resistance, and weight. For decking, PP honeycomb with anti-slip gel-coat surface provides a lightweight, non-corrosive alternative to traditional teak or aluminum. All marine panels feature closed-cell cores with near-zero water absorption, ensuring no osmotic blistering or delamination even after decades of saltwater immersion.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Hull Panel | FRP + PET Foam (Procore 100–200, 20–40mm) | Gel-coat FRP exterior + FRP interior | Structural stiffness, impact resistant, waterproof |
| Deck Panel | PP Honeycomb (10–12mm cell, 20–30mm) | Anti-slip gel-coat or teak-look vinyl | Lightweight, corrosion-free, non-slip |
| Interior Panel | PP Honeycomb (8mm cell, 10–15mm) | HPL or vinyl leather | Lightweight, moisture-proof, decorative |
| Bulkhead | FRP + PET Foam (Procore 120–150, 15–25mm) | FRP both sides | Structural, fire-resistant, waterproof |
Available Panel Configurations
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Performance Highlights
Building & Construction
Modern architecture demands materials that combine aesthetic flexibility with structural performance and energy efficiency. Our composite panels are used in building facades, interior partitions, clean room walls, raised access floors, and modular construction systems. The lightweight nature (3–8 kg/m² vs 15–25 kg/m² for concrete panels) reduces structural load requirements by up to 60%, enabling faster construction and lower foundation costs. For facade applications, aluminum + PP honeycomb panels provide weather resistance and dimensional stability. For interior partitions, HPL or FRP-faced honeycomb panels deliver fire-rated (A2/B1 class), acoustic-insulating wall systems that install 50% faster than traditional drywall construction.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Facade Cladding | Aluminum + PP Honeycomb (15–25mm) | PVDF-coated aluminum both sides | Weather resistant, lightweight, dimensional stable |
| Interior Partition | PP Honeycomb (10mm cell, 40–60mm) | HPL or FRP both sides | Fire-rated, acoustic, lightweight, fast install |
| Raised Access Floor | PP Honeycomb (8mm cell, 30–40mm) | HPL top + steel bottom | Load-bearing, cable management, lightweight |
| Modular Wall | FRP + PET Foam (30–50mm) | Painted FRP or HPL | Insulated, fire-rated, modular |
Available Panel Configurations
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Performance Highlights
Packaging & Flight Cases
Lightweight, impact-resistant composite panels are revolutionizing the packaging and flight case industry. Our PP honeycomb panels replace traditional plywood in reusable transport cases, ATA flight cases, road cases, and protective packaging for sensitive electronics, medical equipment, and military hardware. A typical 12mm PP honeycomb panel weighs just 2.5 kg/m² compared to 8.5 kg/m² for equivalent plywood — a 70% weight reduction that translates directly to lower shipping costs and easier handling. The closed-cell honeycomb core provides superior impact and vibration damping, protecting contents through 500+ shipping cycles without degradation.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Case Wall/Lid | PP Honeycomb (8–10mm cell, 8–12mm) | FRP or aluminum sheet | Impact resistant, lightweight, waterproof |
| Internal Divider | PP Honeycomb (8mm cell, 5–8mm) | Non-woven fabric or foam laminate | Ultra-lightweight, cushioning, CNC cuttable |
| Heavy-duty Base | PP Honeycomb (10mm cell, 15–20mm) | Aluminum both sides | Load-bearing, stackable, forklift-rated |
Available Panel Configurations
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Prefab Bathrooms & Wet Areas
The modular construction industry relies on our waterproof composite panels for prefabricated bathroom pods, shower enclosures, and wet area wall systems. Our FRP-faced honeycomb panels provide a seamless, non-porous surface (Ra < 0.8μm) that resists moisture, mold, and bacterial growth — making them ideal for hotel, hospital, and residential bathroom modules. The smooth gel-coat FRP surface is available in marble, stone, tile, and solid color finishes, eliminating the need for tiling while providing a hygienic, easy-to-clean surface. Panel weight of just 4–6 kg/m² enables entire bathroom pods to be crane-lifted and installed as complete units, reducing on-site construction time by 60–70%.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Shower Wall | PP Honeycomb (10mm cell, 12–15mm) | Gel-coat FRP (marble/stone finish) | 100% waterproof, decorative, seamless |
| Bathroom Floor | PP Honeycomb (10mm cell, 15–20mm) | Anti-slip FRP or vinyl surface | Waterproof, anti-slip, lightweight |
| Ceiling Panel | PP Honeycomb (8mm cell, 8–10mm) | Painted FRP or HPL | Moisture-proof, lightweight, easy to clean |
Available Panel Configurations
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Clean Rooms & Laboratories
Pharmaceutical, semiconductor, and food processing facilities require wall and ceiling panels that maintain strict cleanliness standards. Our FRP composite panels provide smooth, non-porous surfaces (Ra < 0.8μm) that are easy to clean and sanitize, meeting ISO 14644 clean room classifications from Class 1 to Class 8. The seamless panel joints with flush-mounted gaskets prevent particle accumulation and bacterial growth. For GMP Grade A–D environments, our panels are compatible with standard clean room disinfectants including hydrogen peroxide, peracetic acid, and quaternary ammonium compounds. Anti-static options (surface resistivity 10⁶–10⁹ Ω) are available for semiconductor fabrication facilities.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Wall Panel | PP Honeycomb (10mm cell, 50–75mm) | Smooth FRP both sides (white) | Non-porous, easy to clean, GMP compliant |
| Ceiling Panel | PP Honeycomb (8mm cell, 30–50mm) | FRP bottom + aluminum top | Lightweight, cleanable, suspended mount |
| Corner/Coving | FRP molded radius profile | Smooth FRP (radius R25–R50) | No sharp corners, prevents particle buildup |
Available Panel Configurations
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Bus Flooring & Stage Floor Panels
Our high-load capacity PP honeycomb panels serve dual markets: as bus floor panels and coach flooring for public transit vehicles, and as temporary/permanent flooring for stages, exhibition halls, sports arenas, and event venues. For bus applications, the PP honeycomb core (10–12mm cell, 25–35mm thick) with anti-slip rubber or vinyl surface provides a formaldehyde-free, waterproof plywood replacement that withstands daily passenger traffic and regular cleaning with industrial detergents. For event flooring, the modular interlocking system enables rapid setup/teardown while supporting heavy equipment (5+ tons/m²) and intensive foot traffic. All panels are 100% recyclable and reusable for 100+ events.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Bus Floor | PP Honeycomb (10–12mm cell, 25–35mm) | Anti-slip rubber or vinyl surface | Waterproof, lightweight, formaldehyde-free |
| Coach Floor | PP Honeycomb (10mm cell, 25–30mm) | Vinyl leather or carpet surface | Comfortable, easy to clean, lightweight |
| Stage Platform | PP Honeycomb (12mm cell, 30–50mm) | HPL or painted surface | Load-bearing, flat, modular |
| Exhibition Floor | PP Honeycomb (10mm cell, 20–30mm) | Carpet or vinyl surface | Lightweight, reusable, quick install |
Available Panel Configurations
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Furniture & Display Systems
Ultra-lightweight PP honeycomb panels are transforming the furniture and retail display industry. At just 1/5 the weight of equivalent MDF or particleboard, our panels serve as substrates for tabletops, shelving, cabinet doors, exhibition stands, and point-of-sale displays. The exceptional flatness (±0.3mm over 2m) and dimensional stability make them ideal for high-quality lamination with HPL, wood veneer, PVC film, or painted finishes. For portable exhibition systems, the weight savings are transformative: a 2m × 1m display panel weighs just 3–4 kg compared to 15–20 kg for MDF, dramatically reducing shipping costs and enabling one-person setup. All panels are formaldehyde-free (E0 grade) and 100% recyclable.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| Tabletop / Desk | PP Honeycomb (8mm cell, 20–30mm) | HPL or wood veneer + edge banding | Lightweight, flat, scratch-resistant surface |
| Cabinet Door | PP Honeycomb (8mm cell, 15–20mm) | HPL or painted surface | Lightweight, no warping, smooth finish |
| Exhibition Panel | PP Honeycomb (8mm cell, 10–15mm) | Printed PVC film or fabric wrap | Ultra-lightweight, portable, reusable |
| Retail Shelving | PP Honeycomb (10mm cell, 15–20mm) | HPL or painted surface + edge reinforcement | Load-bearing, lightweight, customizable |
Available Panel Configurations
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Performance Highlights
Solar & New Energy
The renewable energy sector demands lightweight, durable structural panels for photovoltaic mounting systems, battery storage enclosures, solar tracker structures, and solar-powered vehicle bodies. Our composite panels provide the structural rigidity needed to support solar arrays while withstanding 25+ years of outdoor exposure to UV radiation, wind loading (up to 2.4 kPa), and temperature cycling from −40°C to +80°C. For battery energy storage systems (BESS), CFRT panels provide fire-retardant enclosures that meet UL 9540A thermal runaway testing requirements. The corrosion-free composite construction eliminates the maintenance burden of traditional steel structures in harsh outdoor environments.
Key Benefits & Technical Advantages
Component-to-Panel Matching Guide
| Component | Recommended Panel | Face Sheet | Why This Combination |
|---|---|---|---|
| PV Mounting Panel | FRP + PP Honeycomb (15–25mm) | UV-resistant FRP both sides | Lightweight, corrosion-free, UV stable |
| BESS Enclosure | CFRT (2–4mm) or FRP + PET Foam | Fire-retardant CFRT or FRP | Fire-rated, structural, thermal barrier |
| Solar Tracker Arm | Aluminum + PP Honeycomb (20–30mm) | Anodized aluminum both sides | Structural stiffness, lightweight, corrosion-free |
Available Panel Configurations
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Don't See Your Industry?
Our composite panels serve many more applications beyond those listed above. With 15+ face sheet options, 6 core material types, and 3 composite methods, we can engineer a custom panel solution for virtually any industry requirement. Contact our engineers to discuss your specific needs.
Contact Our Engineers