Aircraft materials have come a long way over the years. Some of the earliest airplanes were made primarily of wood, such as spruce and ash. Today, however, airplanes are made of a variety of materials, such as carbon fiber, titanium, steel, aluminum alloy and even honeycomb panels. To learn more about honeycomb panels and how they’ve shaped modern aviation, keep reading.
What Are Honeycomb Panels?
Honeycomb panels are structural materials characterized by a honeycomb pattern. They feature two solid outer layers, known as face sheets, that are bonded to a core. The inner core consists of hundreds or even thousands of hexagonal units, resulting in a honeycomb-like appearance.
You can find honeycomb panels in the following aircraft parts:
- Ailerons
- Flaps
- Spoilers
- Cabin floors
- Cabin ceilings
- Luggage bins
- Partitioning walls
- Engine nacelle
- Tail fins
- Wings
Why Honeycomb Panels Have a Hexagonal Core
Honeycomb panels receive their namesake from their hexagonal core. Why do they have a hexagonal core exactly?
With a hexagonal core, honeycomb panels are strong and lightweight — similar to the honeycombs made by bees in nature. They feature two solid, yet thin, walls. These walls provide support for the honeycomb interior. Honeycomb panels, of course, are lightweight because they feature a partially hollow interior consisting of honeycomb units.
At the same time, the honeycomb interior encourages the even distribution of loads. Loads aren’t concentrated in any given area of a honeycomb panel. Instead, they are distributed throughout the panel’s honeycomb units.
Honeycomb panels can withstand bending and compressive forces. Unlike other materials, they won’t crack or succumb to permanent deformation. Rather, honeycomb panels can resist bending and compressive forces thanks to their honeycomb-like interior. These properties make honeycomb panels a popular choice for aircraft components, along with other commercial and consumer products.
What Are Honeycomb Panels Made Of?
You might be wondering what, exactly, honeycomb panels are made of. While they all feature two solid walls with a honeycomb interior, you can find them in different types of materials.
Some honeycomb panels are made of aluminum. They are strong, lightweight and highly resistant to corrosion. Others are made of thermoplastic, such as polypropylene. Thermoplastic honeycomb panels offer a superior level of protection against moisture and chemicals.
You can also find honeycomb panels made of steel. They are typically heavier than their aluminum and steel counterparts, but steel honeycomb panels are able to carry heavier loads.
