Our production process
Inside Our Single‑Step Production Process
Our production process
Our honeycomb core is produced using our proprietary single step core (SSC) manufacturing process. Unlike multi stage methods, SSC forms the honeycomb cell structure and cuts it to height in one continuous, in line process. This keeps tolerances tight and output consistent, even at high production volumes. Our cutting method also creates a larger bonding surface with facing materials, resulting in a stronger connection between core and facing in the final product.
Step 1
Paper infeed
Production starts with paper reels, unwound directly into the machine. The paper itself is the foundation of the honeycomb’s strength, so its weight, moisture content and tensile properties are matched to the intended application before production even begins. A core destined for a structural automotive part needs a different paper specification than one destined for a lightweight furniture panel.
Step 2
Creating Geometry
Glue is applied in an alternating pattern between the paper sheets, forming a laminate that contains the cell geometry. Cell size is not a detail to treat lightly: it affects compression strength, weight and how the core behaves once expanded and laminated into a finished product. What works for a loadfloor does not necessarily work for a cabinet door or a packaging insert. Our team of engineers helps to determine the best cell geometry for your application.
Step 3
Creating Height
The laminate is fed down into the cutter, where it is cut into strips of the desired height of the honeycomb core. Glue is added before cutting, so that the strips can be adhered to the previously cut laminate, creating a continuous honeycomb.
Step 4
Quality Control
Before the honeycomb core is packed, it is expanded in line and checked on cell geometry, height and manufacturing errors. Because this check happens in line rather than as a separate batch process, deviations are caught early. Our quality control standards meet those of today’s furniture and automotive industries, where inconsistent material can mean machine stops and line disruptions downstream.
Step 5
Packaging
After quality control, the honeycomb core is compressed, which eliminates up to 90% of the transport and inventory requirements compared to shipping it expanded. This is delivered unexpanded on pallets, then expanded on site at the customer’s facility, right before it enters their own production process. For customers running high volume lines, this compact delivery format is often what makes it possible to reduce safety stock without adding risk to supply.
