honeycomb core material before expansion
Compression Molded Honeycomb Fiber-Core Panels

Our compression molded fiber core panels are an amazing technological achievement. At LoadFloors.com, we partnered with Covestro to revolutionize the production of load floor panels. The result features a honeycomb sandwich core and reinforced sheeting material that gives it its structure.

The reinforced sheeting was developed and designed to allow compression molders to quickly wet out the bottom and top of the surface of the composite panel. The honeycomb core gives it a base that is lightweight and yet offers much more strength than other fiberglass or aluminum honeycomb panels can offer.
The geometry of the honeycomb structure allows for a minimal amount of material while retaining strength and support. The hollow cells in between the honeycomb structure allow for an extremely light weight when compared to other types of load floors. In engineering terms, the honeycomb core allows for minimal density. This keeps relatively high out-of-plane compression properties. The strength-to-weight ratio is impressive and is widely used in the aerospace industry, which adopted the use of similiar construction in the 1950s.
Most honeycomb sandwich structured composites have a very high strength-to-weight ratio, are corrosion resistant, are thermally insulated, have a good thermal stability, have excellent fatigue and creep performance, and also possess excellent dielectric properties. Most aerospace-grade fiber honeycomb structures typically have great flammability properties as well.
So how can something so simply perfect yet brilliantly complex come to be? Who had the engineering mind to conceive honeycomb core and honeycomb core material? Often times one need look no further than Mother Nature.
The structure of a beehive, with its hexagonal honeycomb structure, is one of the strongest known to man. Did it arrive in nature by trial and error over thousands of years? A freak of evolution? A lucky strike for bees? Whatever the case, mankind is grateful, as the honeycomb structure has been used in so many different ways since discovering its usefulness.
A honeycomb core that is engineered into our load flooring is a honeycomb sandwich composite that is very efficient in terms of weight used to stength achieved. The honeycomb core panels increase the part stiffness at a much lower rate and weight than other monolithic composite materials. It has a very high compressive strength towards the direction of the walls of the cell. The honeycomb structure has a high shear strength in the plane direction that is perpindicular to the walls. Perpindiucalar to the cell walls it actually has a rather low strength, however this is reinforced by the outer skin/wall.
Please take a look at our photo gallery and watch our video. You will find that our composite honeycomb load floors are an excellent choice for your compression molding processes!

Loadfloors Honeycomb Fiber Panels
Huge fiber inventory ready for processing.
Finished, carpeted, and installed Loadfloors fiber core trunk panels.
Trimmed Honeycomb Fiber-Core-Panel
Finished and Carpeted Loadfloors Fiber trunk panel
Honeycomb Fiber-Core-Panel sandwiched
Honeycomb core material processing line
Honeycomb Fiber-Core-Panel
Finished and carpeted Loadfloors Honeycomb Fiber trunk panel.
Loadfloors Honeycomb Core before expansion.
Interior of a Loadfloors Composite Honeycomb Fiber-Core-Panel
Honeycomb Fiber-Core-Panel sandwiched and processing
Honeycomb core materials processing before trimming
Large inventory of materials in stock
Honeycomb fiber material waiting for processing.
Honeycomb Core being trimmed to size


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We are excited to work with you on your next project, and look forward to adding you to our growing list of companies who have used our honeycomb core in a variety of applications. Here are some of those companies:
Automobile Manufacturers that utilize honeycomb fiber-core-panels.