3D CORE,lightweight components,honeycomb

3D|CORE™ TECHNOLOGY

WHY LIGHTWEIGHT CONSTRUCTION WITH 3D|CORE™?

Lightweight construction is the solution for our future. Saving mass can not only increase material efficiency and reduce resource consumption, but it often also improves products. This saves manufacturing and operating costs and, by using valuable resources sparingly, protects the climate at the same time: a lighter machine or a lighter vehicle requires less energy to operate. Thus, lightweight construction is a key factor for tomorrow's society and industry.

This is where 3D|CORE™ comes in: our high-performance composite materials serve as the basis for outstanding lightweight components. 3D|CORE™ is the key technology for meeting the challenges of energy and material efficiency while increasing the performance and productivity of machines and systems.

We pick up where others leave off: lightweight components, little effort, low costs.

3D|CORETM is a patented honeycomb structure that is inserted into a foam core and runs through the entire foam core. The structure consists of single honeycomb foam bodies that are connected to each other with small bridges and allow a high flexibility of the foam core. Between the individual honeycomb foam bodies are interstices that serve as, already integrated, flow aids and support the filling process with a liquid matrix. Once the 3D|CORETM structure (interstices) is filled with a liquid matrix and cured, the foam core retains its shape and develops excellent technical properties, such as improved shear and compression properties. The face layers, on both sides of the foam core, are bonded together via the honeycomb structure. This prevents delamination, as well as complete failure of the component.


  •  Significant savings in resin consumption compared to other foam cores (e.g. for flow aid and peel ply)

  • Calculable resin consumption (no additional resin without technical benefit)
  • Intermediate vacuum is not required, as 3D|CORETM already conforms to the mold at the beginning
  • Avoidance of delamination of the surface layers
  • Homogeneously filled component
  • Low final component weight
  • Durable components
  • Sustainable manufacturing process
  • Immense savings of consumables possible (e.g. flow aid, peel ply, spray adhesive)


BENEFIT FROM OUR INNOVATIVE HONEYCOMB TECHNOLOGY TO IMPLEMENT YOUR CO² SPECIFICATIONS!

3D|CORE™ – UNIQUE PROPERTIES

3D|CORETM is the perfect basis for ultra-light high-performance composite components. Only the combination of the unique properties of 3D|CORETM, a minimal material input , low process energy and integrated recycling concept result in a sustainable solution with which we help you to reach your CO2 targets.

More flexibility and easy handling:

Due to the three-dimensional formability, convex as well as concave components can be produced without pressure and heat.

Integrated filling and venting system (flow aid effect):

The structure guarantees ideal filling with resin and thus optimum wetting of the surface layers.

An additional flow aid is not required.

Surface layers are bonded together:

The cured resin forms a resin bridge that connects the surface layers to each other. This prevents delamination of the face sheets and prevents complete failure of the component.

Double-T beam effect:

The cured resin around the individual honeycomb foam bodies forms individual double-T beams. These enable the absorption of very high forces.

  • approx. 1000% more compression strength
  • approx. 500% more flexural strength
  • approx. 300% more shear strength

3D|CORE™ – PERFORMANCE STRUCTURES

3D|CORETM is available in three different structures. These are used for core optimization and can also be used for partial stiffening of critical components.


HEXAGON STRUCTURE

Improvement of the 3D|CORE™ HX structure compared to standard foam cores:

  • Technical properties of the core by 100%, flexibility by 100%
  • Peel strength of the fiber layers by 100%
Available in XPS and PET foam.

RHOMBUS STRUCTURE

Improvement of the 3D|CORE™ RB structure compared to standard foam cores:

  • Technical properties of the core approx. 200%, flexibility approx. 200%
  • Peel strength of the fiber layers about 150%

Available in XPS and PET foam.



DELTA STRUCTURE

Improvement of the 3D|CORE™ DT structure compared to standard foam cores:

  • Technical properties of the core approx. 300%, flexibility more than 300%
  • Peel strength of the fiber layers about 200%

Available in XPS and PET foam.