ThermHex Waben GmbH from Halle is making honeycomb cores out of polypropylene (PP) using a patented procedure. They are used in sandwich structures which are usually consisting of a honeycomb core or polymer foam with cover layers made of fiber-reinforced plastics. Thermoplastic honeycomb cores are light and cost-effective, but have a limited bending and denting strength compared to more expensive honeycomb cores, which is why they are used mainly for cladding and interior components that are under less stress.

ThermHex Waben has now launched a research project in collaboration with the Fraunhofer Institute for Microstructure of Materials and Systems (IMWS) to improve these honeycomb cores. It is taking a new approach in which the thermoplastic honeycomb cell walls are themselves made from a honeycomb sandwich. This significantly increases the stability of the honeycomb core at the same weight or even lower. In addition, the researchers are intending to investigate the use of structured cover layers that offer better load distribution and surface quality.

The project is being funded by the state of Saxony-Anhalt and the European Regional Development Fund (ERDF) .