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Core Material

HexWeb® honeycomb and foam core from Hexcel — the world’s largest manufacturer of structural honeycomb. Aluminum, aramid fiber (Nomex®), and polyurethane foam cores in over 700 varieties for aerospace sandwich structures. The core that makes a sandwich panel 37× stiffer than solid metal at a fraction of the weight.

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Coast-Line stocks Hexcel HexWeb® core materials — honeycomb sandwich structures in aluminum, aramid fiber (Nomex®), and polyurethane foam configurations. Hexcel was the first company in the USA to manufacture expanded honeycomb on a commercial scale and today produces over 700 varieties. HexWeb® core is the choice of every major commercial aircraft manufacturer — Boeing (737, 747, 777, 787), Airbus (A320, A350, A380), and military/defense programs worldwide. 

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Why Honeycomb Sandwich Construction?

Minimum Weight

A sandwich panel with honeycomb core achieves the strength and stiffness of solid metal at a fraction of the weight — critical for every aircraft component.

37× Stiffer

A sandwich panel with a thin core is up to 37× stiffer in bending than a solid plate of the same weight. The core separates the face sheets and acts as a structural I-beam web.

Aerodynamic Surfaces

Honeycomb sandwich panels provide the smooth, rigid aerodynamic surfaces required for control surfaces, fairings, floors, and interior panels.

Multifunctional

Beyond structure: honeycomb provides sound attenuation (Acousti-Core®), radar transparency (radomes), energy absorption, and thermal insulation in a single component.

Aluminum
Aluminum Honeycomb
5052 · 5056 Alloy · CR III · CR-PAA
Highest compressive and shear strength per density — primary structural applications
5052 general purpose · 5056 ~20% stronger
CR III or CR-PAA corrosion protection for aerospace environments
Flex-Core® for curved structures; Rigicell® corrugated for edge strength
Excellent thermal conductivity and electrical conductivity
Aramid Fiber
Aramid / Nomex® Honeycomb
HRH-10® · HRH-78® · KOREX®
Non-metallic — no corrosion, no galvanic issues with carbon skins
Fire resistant — does not melt, self-extinguishing (FST compliant)
Interior aircraft panels standard: 737, 777, 787, A320, A350, A380
Excellent dielectric properties for radomes and RF-transparent structures
Heat-formable to complex compound curves
Polyurethane
Polyurethane Foam Core
HexWeb® TPU™ · Foam Sheet
Closed-cell foam — moisture resistant, non-wicking
Energy redirection and fatigue resistance unique to polyurethane
Easiest to machine, cut, and shape of all core types
Available in multiple colors for identification of density grades
Best for cushioning, impact-tolerant, and non-structural applications

HexWeb® Cell Configurations

Regular Hexagonal

Standard cell shape for maximum strength efficiency. Equal properties in both L and W directions. Most widely specified for structural aerospace applications.

OX-Core® (Over-Expanded)

Hexagonal cells over-expanded in the W direction creating a rectangular shape. Allows the core to curve easily in the L direction — ideal for cylindrical and singly-curved panels.

Flex-Core®

Highly flexible core for complex and compound curved structures. Conforms to tight radii and double-curved surfaces. Available in aluminum and non-metallic materials.

Double-Flex / CROSS-CORE®

Bi-directional corrugated aluminum construction providing equal drape properties in both L and W directions. Used for doubly-curved structural components.

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Aluminum Honeycomb

Aluminum Honeycomb
Hexcel · HexWeb®
HexWeb® CR III — Corrosion-Resistant Specification Grade Aluminum
The aerospace industry standard aluminum honeycomb — 5052 or 5056 expanded aluminum alloy honeycomb treated with the HexWeb® CR III organo-metallic polymer corrosion-resistant coating. Meets the requirements of MIL-C-7438 and AMS-C-7438 for corrosion resistant aluminum honeycomb. The CR III coating provides superior salt spray resistance far exceeding typical conversion coatings — shear strength retention after 350°F heat aging for 500 hours combined with 30-day salt spray exposure is approximately 88% of room temperature properties. Available in a wide selection of cell sizes (1/8" to 3/8") and densities (1.6 to 12.0+ pcf). 5056 alloy provides approximately 20% higher strength than 5052 for more demanding structural requirements. Designation format: CR III — Cell Size — Alloy — Foil Thickness — Density.
Aerospace Standard MIL-C-7438 · AMS-C-7438 5052 · 5056 Alloy CR III Corrosion Coating 1.6–12.0 pcf Density Range
Designation System
CR III — 3/16 — 5052 — .002N — 3.1
CR III = corrosion coating type 3/16 = cell size (inches) 5052 = aluminum alloy .002 = foil thickness (inches) N = non-perforated cells 3.1 = density (pcf)
Common Cell Sizes
1/8" (3.2mm)High density, fine surface finish
3/16" (4.8mm)Most widely specified aerospace
1/4" (6.4mm)Structural panels, floors
3/8" (9.5mm)Lower density, large panels
Aluminum Honeycomb
Hexcel · HexWeb®
HexWeb® Aluminum Flex-Core® — Formable Aluminum
Highly flexible aluminum honeycomb that can be formed to complex curved shapes without machining — conforms to curved molds and bond tools by hand pressure. Eliminates the need for core splicing on curved structures. Cell geometry is designed to allow the core to flex and conform in both L and W directions, enabling fabrication of curved panels, radomes, fairings, and doubly-curved structural skins that would otherwise require multiple core splice joints.



Formable Without Machining Curved Structures Radomes · Fairings No Splice Joints
Aluminum Honeycomb
Hexcel · HexWeb®
HexWeb® Rigicell™ — Corrugated Aluminum
Corrugated aluminum honeycomb constructed from flat and corrugated aluminum foil — eliminates crush strength loss at unsupported edges, a key advantage over standard expanded honeycomb at panel edges and cutouts. Available in diameters from 1/2" to 30" and lengths from 1/2" to 36" for Tube-Core® energy absorption cylinders. Also used for RF shielding, air directionalizing, and high-edge-loaded structural applications.





Corrugated Construction No Edge Crush Loss Energy Absorption RF Shielding
Aluminum Honeycomb
Hexcel · HexWeb®
HexWeb® CR-PAA™ — Phosphoric Acid Anodized Aluminum
Premium aerospace aluminum honeycomb with phosphoric acid anodized (PAA) surface treatment — providing superior bond strength, salt spray resistance, crack propagation resistance, and hot/wet environment performance versus standard AMS-C-7438 core. Designed for aircraft structures exposed to the most demanding environmental conditions. In environmental peel testing at 140°F / 100% humidity for 30 days, CR-PAA outperforms standard AMS core significantly. Available in 5052 and 5056 alloys across a wide range of cell sizes and densities.
Premium Environmental Performance PAA Surface Treatment Hot/Wet Environment 5052 · 5056 Alloy
02

Aramid Fiber Honeycomb

Aramid Honeycomb
Hexcel · HexWeb®
HexWeb® HRH-10® — Nomex® Aramid/Phenolic Aerospace Grade
The most widely used non-metallic honeycomb in commercial aviation — HRH-10® is manufactured from Nomex® aramid fiber sheets bonded at the nodes with a thermosetting adhesive, expanded to hexagonal or OX-Core® configuration, and dipped in phenolic resin. Most interior panels of commercial jets — Boeing 737, 747, 777, 767, 787 and Airbus A320, A350, A380 — are made with HRH-10® primarily because of its resilience, small cell size/low density combination, and fire resistance. Exterior applications include radomes, fairings, helicopter blades, and flaps. Complies with SAE specifications AMS-3711 and AMS-81986 / MIL-C-81986. Available in hexagonal, OX-Core®, and Flex-Core® configurations. Can be machined or heat-formed to complex compound curvatures. Service up to 350°F.
Most Widely Used Interior Core Nomex® Aramid + Phenolic AMS-3711 · AMS-81986 737 · 777 · 787 · A320 · A380 Fire Resistant to 350°F Hexagonal · OX · Flex-Core®
HRH-10® Designation
HRH-10 — 1/8 — 3.0
HRH-10 = Nomex® aramid/phenolic 1/8 = cell size (inches) 3.0 = density (pcf)
Key Properties
MaterialNomex® aramid + phenolic resin
Fire ResistanceSelf-extinguishing (FST)
Max Service Temp350°F (175°C)
Galvanic RiskNone — non-metallic
DielectricLow ε — suitable for radomes
Cell ShapesHex · OX-Core® · Flex-Core®
Aramid Honeycomb
Hexcel · HexWeb®
HexWeb® HRH-78® — Nomex® Commercial Grade
Commercial grade Nomex® paper dipped in phenolic resin — the non-aerospace economy version of HRH-10® for marine, rail, and non-aerospace applications where the full aerospace specification of AMS-3711 is not required. Provides the same fire resistance, non-metallic construction, and light weight as HRH-10® at a lower cost point. Used in marine hulls, rail interiors, sports equipment, architectural panels, and non-structural aircraft interiors.


Commercial Grade Nomex® + Phenolic Marine · Rail · Sports Cost-Effective
Aramid Honeycomb
Hexcel · HexWeb®
HexWeb® KOREX® — Para-Aramid/Phenolic
Para-aramid fiber honeycomb offering improved strength-to-weight ratio and/or lower moisture absorption than standard Nomex® (HRH-10®). The KOREX® fiber paper is dipped in phenolic resin. Used in applications where the higher inherent moisture resistance of para-aramid provides a processing or service life advantage over Nomex® — particularly in hot/wet service environments and applications with strict moisture ingress control requirements.
Para-Aramid Fiber Lower Moisture Absorption Higher Strength/Weight vs HRH-10 Hot/Wet Environments
Aramid Honeycomb
Hexcel · HexWeb®
HexWeb® HRH-36 — High-Performance Wide Range
High-performance non-metallic core available in a wide range of densities, suitable for most composite sandwich applications. Can be readily heat-formed to help produce complex components and offers a weight reduction over higher-density Nomex® honeycomb cores. Available in panel sizes 1250 × 2500 mm for thicknesses up to 860 mm. Estimated minimum average mechanical properties per MIL-STD-401.


Wide Density Range Heat Formable Up to 860mm Thick Complex Components
03

Polyurethane Foam Core

Polyurethane Foam
Hexcel · HexWeb®
HexWeb® TPU™ — Thermoplastic Polyurethane Honeycomb
HexWeb® TPU™ is Hexcel's thermoplastic polyurethane honeycomb — a unique core material offering properties not available in aluminum or aramid honeycomb. The polyurethane construction provides exceptional energy redirection, fatigue resistance, and flexibility compared to rigid honeycomb cores. TPU's inherent elasticity allows the core to absorb and redirect impact energy rather than crush irreversibly, making it the preferred choice for applications requiring repeated impact tolerance. Available in multiple colors for easy visual identification of density grades. Machineable to shape, bondable with standard adhesive systems, and moisture resistant (closed-cell construction resists water ingress). Used in seat structures, floor coverings, impact-absorbing panels, and secondary structural components where energy management is as important as structural performance.
Energy Redirection & Fatigue Resistance Thermoplastic Polyurethane Flexible — Repeated Impact Closed-Cell — Moisture Resistant Multiple Colors / Densities
TPU™ vs Rigid Honeycomb
Energy AbsorptionRedirects (recovers) vs. crushes
Fatigue LifeSuperior — elastic, not brittle
Moisture ResistanceClosed-cell — non-wicking
MachinabilityExcellent — saws, routers
Bond SystemsCompatible with standard adhesives
IdentificationColor-coded by density grade
Polyurethane Foam
Hexcel · HexWeb®
Polyurethane Foam Sheet — Closed-Cell Structural
Closed-cell polyurethane foam in sheet form for sandwich panel core applications where ease of fabrication is prioritized. Non-wicking — moisture does not travel through the closed-cell structure as it does in open-cell or honeycomb cores. Available in density grades from approximately 2 lb/ft³ to 20+ lb/ft³. Easy to cut with hand tools, CNC routers, or hot wire. Bonds well with epoxy, polyurethane, and methacrylate adhesive systems. Used in marine, wind energy, and aerospace secondary structures where machineability and moisture resistance are critical.


Closed-Cell Sheet Form Multiple Density Grades Easy Fabrication Non-Wicking CNC Machinable
Polyurethane Foam
Hexcel · HexWeb®
Acousti-Core® — Sound Attenuation Honeycomb
Acousti-Core® is a honeycomb core — available in aluminum and HRH-10® aramid base materials — filled with fiberglass batting and used with perforated or porous facing skins for lightweight sound absorption panels. Provides significant structural integrity along with acoustic absorption in a single panel component. Available in standard cell sizes of 3/16" and larger. Used in aircraft nacelles, engine ducts, cabin acoustic liners, and any structural panel where noise reduction is a design requirement alongside weight efficiency.
Acoustic + Structural Fiberglass Batting Fill Al or HRH-10 Base Nacelles · Engine Ducts Perforated Facing

Why Source HexWeb® Core from Coast-Line?

Authorized Hexcel Distributor

Genuine HexWeb® material with full Hexcel mill traceability. COC and COA documentation available on request — meeting AS9120 quality requirements.

OEM Specifications

HexWeb® CR III, CR-PAA, and HRH-10® products qualified to Boeing BMS, Airbus AIMS, MIL-SPEC, and SAE AMS specifications across commercial, defense, and general aviation programs.

Custom Cut Panels

Hexcel can supply panels machined or cut to your specific L, W, and T dimensions. Tapers, chamfers, double reliefs, and complex contour machining available directly from the manufacturer.

700+ Varieties

Hexcel produces more varieties of structural honeycomb than any other manufacturer. If a standard product doesn't meet your requirement, custom specifications are available.