Nomex® Honeycomb: How Much Do You Know About the Space-Age Material?
Every industry has a handful of products and services that seem to stand out above the rest. Nomex® honeycomb is one such product in the composites industry. It is a preferred material for aerospace design, though it has applications in other industries as well.
How much do you know about Nomex honeycomb? If your knowledge is limited, we encourage you to do some research. Nomex honeycomb could be a material that completely changes your design or manufacturing processes.
Nomex Honeycomb in a Nutshell
Nomex honeycomb is a high strength, lightweight composite used as a core material. It’s made from Nomex paper, which just happens to be a rather interesting product itself. The paper is made of aramid fibers and then fashioned into a honeycomb structure consisting of chambers laid out in a hexagonal pattern. Think of a beehive and you’ll know exactly what Nomex honeycomb looks like.
It is great as a core material thanks to its key properties:
- Excellent strength and stiffness
- Minimal weight
- Excellent fire resistance
- Chemical stability
Nomex honeycomb is also able to maintain its mechanical properties even under extreme conditions. In simple English, it can stand up to a lot of punishment without failing. That’s why it is used so extensively in aerospace.
How the Material Is Made
Detailing Nomex honeycombs’ entire manufacturing process would be impractical for a single blog post. Still, we can explain in general terms how the product is made. It starts with Nomex paper and adhesive.
Flat sheets are laid out and addressed with adhesive. The adhesive is applied in a staggered pattern before the sheets are stacked for curing. Once cured, the manufacturer left with a solid block of honeycomb paper. We call this ‘honeycomb before expansion’ (HOBE).
Each block is then expanded to create the unique structure Nomex honeycomb is known for. Next, the expanded material is saturated with a heat-resistant phenolic resin and cured once again. This second curing stabilizes and strengthens the honeycomb structure.
Finally, the block is cut into sheets based on the intended purpose. Thickness and cell size can be tailored to various needs. In addition, Nomex honeycomb can also be combined with foam for certain applications.
Endless Possibilities for Application
Nomex honeycomb is most often used as a core material for composite panels. The honeycomb is sandwiched between two panels made from another composite material. In aerospace, Nomex honeycomb is a popular option for interior sidewalls, flooring, ceilings, and galleys. It’s also deployed in fuselage components and cargo hold areas.
Industries outside of aerospace appreciate Nomex honeycomb as well:
- Motorsports – Motorsports engineers appreciate the specific material properties that make for better car panels, crash structures, and racing shells.
- Rail – Nomex honeycomb is deployed in rail transportation to improve fire safety and reduce weight. It is commonly used in floors, ceilings, and doors.
- Marine – The marine industry appreciates Nomex honeycomb for the same reasons. Designers use it to build better hulls and bulkheads.
If you know where to look, you can even find Nomex honeycomb deployed in everything from telecommunications equipment and temporary shelters to snowboards and skis.
A Material Worth Exploring
Nomex honeycomb is a material worth exploring for any manufacturer that utilizes composite panels. It offers a high strength-to-weight ratio, excellent fire resistance, corrosion and moisture resistance, and good electrical insulation. Best of all, it’s very easy to work with.
Axiom Materials can be your source for Nomex honeycomb. If you have any questions about it or deploying it for your application, don’t hesitate to contact us. Nomex honeycomb is a fantastic material we believe in wholeheartedly.