Aluminum honeycomb core, as a lightweight and high-strength architectural material, requires precise manufacturing processes to ensure product quality and performance. This article details the standard production workflow for construction-grade aluminum honeycomb cores.
1. Raw Material Preparation
Aluminum Foil Selection:
Uses 3003/5052 series aluminum alloy foil
Thickness: 0.03–0.1mm
Tensile strength ≥150MPa
Pre-Treatment:
Degreasing (alkaline solution, pH 9–11)
Chemical oxidation to form a 0.5–1μm oxide layer
Slitting:
Wide-format foil (1200–1500mm) slit into designed widths (10–50mm)
2. Core Formation Process
Adhesive Coating:
Modified epoxy resin adhesive
Double-sided coating: 8–12g/m²
Patterned roller transfer ensures uniformity
Lamination & Pressing:
Temperature: 120–150°C
Pressure: 0.8–1.2MPa
Duration: 30–60 minutes
Forms standard hexagonal cells (side length: 3–10mm)
Stretching & Curing:
Stretch ratio: 300–500%
Simultaneous heat curing (180°C × 2h)
3. Post-Processing
Precision Cutting:
CNC waterjet cutting (±0.2mm accuracy)
Maximum panel size: 6000 × 1500mm
Surface Treatment:
Anodizing (coating thickness: 10–15μm)
PVDF coating (3-coat, 2-bake process)
Quality Testing:
Flatwise compression strength (≥1.5MPa)
Fire resistance (GB8624 Class A2)
Thermal conductivity (≤0.05W/(m·K))
4. Key Quality Controls
Environment: Controlled temperature (23±2°C) and humidity (50±5% RH)
In-process inspection: X-ray scanning for structural integrity
Final verification: Salt spray testing (2000 hours per batch)
The industry is advancing toward larger formats (8m+ panels) and thinner foils (0.02mm), while eco-friendly water-based adhesives now account for 40% of production. Manufacturers mastering these processes gain a competitive edge in facades, ceilings, and other architectural applications.
