Recreational Vans
Lightweight honeycomb panels belong to the sandwich composite family. Two thin facesheets are bonded to a hexagonal core that looks like a beehive when viewed from the edge. The geometry spaces material away from the neutral axis, so the skins take the bending loads while the core resists shear and keeps the skins apart. The result is a panel that feels exceptionally rigid for its mass, often matching the stiffness of much thicker plywood at a fraction of the weight.
Stiffness scales strongly with the distance between the skins, which is the core thickness. A thicker core raises bending rigidity without adding significant mass, because the core density is very low. Typical cores range from 6 to 25 millimeters for interior use, while structural floors or bulkheads may go thicker. Skins can be aluminum sheet, fiberglass reinforced polymer, carbon fiber, or laminates that accept finishes like vinyl and HPL.
The cellular structure also damps vibration and can quiet panel buzz in mobile environments. Compared to solid boards, the sandwich approach keeps panels flat over temperature swings and humidity changes, which reduces warping in doors, cabinets, and wall systems.
Core materials drive weight, cost, and durability. Aluminum honeycomb offers the best stiffness to weight and excellent fire performance. It resists creep and heat, making it reliable around power systems and heaters. Polypropylene honeycomb is lighter and more affordable than aluminum, with good moisture resistance and easy machinability, and it pairs well with fiberglass skins for interior furniture.
Facesheets set the surface durability and load capacity. Aluminum skins are tough, conductive, and easy to attach via rivets or bonded inserts. Fiberglass skins can be painted or laminated, isolate heat, and resist corrosion. Carbon fiber skins deliver the highest stiffness for weight, best saved for critical parts like bed platforms or removable bulkheads where every gram counts.
Adhesive selection is the heartbeat of a long lasting panel. Two part epoxies and polyurethane systems are common, chosen for gap filling properties, peel strength, and service temperature. Surface prep matters. Scuff the facesheets, clean with appropriate solvents, and use primed or corona treated plastics to boost adhesion. In production, vacuum bagging or press curing ensures uniform bond lines and keeps panels flat.
Design panel thickness to match load path, not just span. For a cabinet door, a 10 to 15 millimeter core with fiberglass skins often feels rock solid and stays quiet in motion. For a bed system, go thicker where it spans long distances. Where localized loads occur, such as hinges, latches, or roof rail interfaces, use hardpoints. These can be bonded aluminum blocks, potted inserts, or perimeter rails that spread fastener loads into the skins rather than crushing the core.
Edges need closure for durability and a finished look. Options include bonded aluminum or ABS edge extrusions, epoxied hardwood strips, or filled and capped composite edges. Sealed edges stop moisture ingress and make panels resistant to cleaning solvents and road grit. When routing cutouts for windows, vents, and service hatches, reinforce the opening with a bonded frame to maintain stiffness.
Thermal and acoustic behavior is another advantage. Honeycomb cores trap air, offering useful insulation without bulk. When combined with foam backing or mass loaded vinyl layers, panels can quiet road noise. For fire safety, many aluminum honeycomb systems can be specified to meet stringent flammability and smoke tests used in transportation interiors. Always confirm the fire rating needed for your use case before ordering material.
Finishing options are broad. You can laminate decorative films, spray coat fiberglass skins, or apply wrapped textiles. Many builders prefer pre finished facesheets to reduce shop time and ensure a repeatable look. For wet zones like showers or rear gear bays, select waterproof skins and non wicking edge closures.
Aluminum honeycomb provides the highest temperature tolerance and predictable mechanical behavior. It is ideal where loads concentrate or where you need thin panels that still carry weight. Polypropylene honeycomb is the go to for lightweight furniture and partition walls due to its easy cutting and cost efficiency. Paper based honeycomb can be used in strictly dry, interior only applications where budget is priority.
Aluminum skins accept rivets, clinch nuts, and structural adhesives. Fiberglass skins take well to epoxy and polyurethane and can be laid up with additional fabric around hardpoints to build local strength. Bond line thickness should be controlled with spacers or glass beads to avoid starved joints and ensure long term peel strength.
Pre plan service runs before bonding panels in place. Use removable fasteners where maintenance is expected, and rely on adhesive bonding where you need silence and stiffness. Isolate dissimilar metals with sealant or isolators to prevent galvanic corrosion in damp environments.
These panels thrive wherever weight reduction improves range, handling, or payload. In vans and towables, they create rigid beds, cabinets, bulkheads, and wall modules without overloading the platform. Floors benefit from high stiffness and minimal deflection across wide spans, keeping doors aligned and hardware quiet. Removable modules made from honeycomb are easier to lift and reconfigure compared to plywood builds, which makes seasonal layout changes practical.
Because the structure is stable through humidity cycles, doors stay true and latches remain aligned after long trips. The same stability supports precise panel gaps and a refined fit. When choosing attachment strategies, mix bonded seams for silence with mechanical fasteners where you need field serviceability. A small amount of design attention to edge closures and insert planning pays big dividends in longevity.
When a build calls for weight savings and lasting stiffness, our team selects honeycomb panels to hit defined performance targets. We specify core type, facesheet material, and insert strategy to match how you travel and what you carry. For mountain bikes, surf gear, or moto cargo, we use hardpoints and perimeter rails that prevent crushing and keep panels quiet over rough roads. For comfort areas, we pair composite panels with acoustic underlays that tame resonance and road hum.
In Fayetteville Arkansas, we prototype layouts that balance weight, storage, and service access. Our fabrication capability includes precision cutting, bonding, and edge finishing so the final assembly looks clean and stands up to use. If you want a lighter interior without giving up strength, we can engineer a panel package that fits your platform and timeline.
Ready to go lighter and stronger If you are planning a custom interior and you want the efficiency benefits of lightweight honeycomb panels, we can help you evaluate materials, stiffness targets, and attachment details. Our process focuses on real world use and quiet, serviceable construction.
We design and build complete custom vans, partial upfits, overland rigs, towable interiors, commercial van solutions, and precision fabrications. Every project is planned around how you travel and what you need on the road. Submit the form to start a consult and get a tailored estimate from OZK Customs in Fayetteville Arkansas.
Ready to design a lighter and stronger interior with honeycomb panels? Tell us how you travel and we will engineer a custom van that saves weight without sacrificing durability. Submit the form to schedule a design consult and get a tailored estimate from OZK Customs in Fayetteville Arkansas.
ADDRESS:
6159 E Huntsville Rd, Fayetteville, AR 72701
PHONE:
(479) 326-9200
EMAIL:
info@ozkvans.com