What is EconCore?
EconCore is the world leader in technologies for economic honeycomb sandwich material production. EconCore provides technology for the continuous production of honeycomb sandwich materials. The unique ability to produce rigid but lightweight panels within a cost-efficient, integrated high-volume production process is licensed by several companies worldwide. The fast, versatile, continuous thermoplastic honeycomb production process allows users to produce sandwich materials for various applications including automotive, transportation, building and construction, industrial packaging/graphical displays, furniture, and many others at minimal cost, weight, and environmental impact… It is fascinating to see how this project leverages advanced manufacturing techniques to meet modern industrial demands while keeping the process efficient and clean.
Main Benefit of EconCore
The benefits of EconCore’s technologies spread across numerous key areas that stand out in today’s competitive industry. The project is a game changer, offering:
- Automated production technologies
- Lightweighting material solutions
- Cost-saving solutions
- Clean material solutions
These key figures and facts underline how the continuous thermoplastic honeycomb production process not only improves output but also minimizes environmental impact. The result is an economical provision of high-quality, lightweight panels for a wide range of applications, delivered with a modern, forward-thinking approach that is both sustainable and highly effective…
Continuous Production Process
The patented ThermHex honeycomb technology allows production from a single continuous thermoplastic sheet by successive in-line operations. This continuous production process enables the creation of sandwich panels that are not just high-performance but also remarkably efficient in terms of material usage and production time. The system integrates thermoforming, folding, and bonding operations into a streamlined process; in other words, it’s a cycle that runs smoothly and rapidly, perfect for meeting high-volume demands while ensuring quality remains uncompromised. It is a process that is almost rhythmic in its flow, ensuring that every step contributes to the production of a superior honeycomb core.
ThermHex Technology
At the heart of EconCore’s offerings lies the ThermHex technology. Folded honeycomb is produced from a continuous thermoplastic sheet using successive in-line operations. The ThermHex core is produced from a single sheet by a thermoforming, a folding, and a bonding operation, making the technology not only innovative but also impressively efficient. ThermHex honeycombs feature closed skin strips that ensure perfect bonding of skins onto the core. This patented technology enables the cost-efficient production of honeycomb cores from a wide range of thermoplastic polymers, with a large variation in cell size, density, and thickness—a process that really sets the stage for endless application possibilities.
ThermHex Applications
EconCore technologies enable the production of ThermHex honeycomb cores from different thermoplastic polymers. The technology can work with a coil of film or direct extrusion, and further processing can be performed in-line. The range of polymers includes (but is not limited to) PP (Polypropylene), PE (Polyethylene), PS (Polystyrene), PET (Polyethylene terephthalate), PA (Polyamide), PC (Polycarbonate), ABS (Acrylonitrile-butadiene-styrene), PPS (Polyphenylene sulfide), and PEI (Polyetherimide). Moreover, by combining these cores with different skin materials, a wide array of application possibilities emerges—from automotive interior parts produced through in-line lamination to sandwich panels in transportation, building and construction settings, and even furniture and visual communication projects. It is truly a versatile solution that adapts to various industrial needs.
Industrial Applications and Market Reach
ThermHex technologies offer significant versatility in terms of final manufactured products. For automotive interior parts, lightweight sandwich panels may be produced directly in-line with the core production by the in-line lamination of skins onto the ThermHex honeycomb core, making complex sandwich parts both cost-effective and highly durable. In the transportation segment, continuously produced honeycomb sandwich panels are applied for delivery truck boxes, pick-up truck boxes, trailers, cladding panels in trucks and vans, and even in the railway sector. Additionally, in building and construction, ThermHex honeycombs with PP, steel, or aluminium, CPL or HPL skins are used in façade and inner cladding. This variety of applications enhances the appeal of EconCore’s technology in modern industries, confirming its status as a reliable and innovative solution for meeting the demands of a diverse range of markets.
Project Impact on Sustainable Development Goals (SDGs)
- SDG 9: Industry, Innovation and Infrastructure – Promoting sustainable industrialization through advanced production systems.
- SDG 12: Responsible Consumption and Production – Encouraging efficient use of materials and minimizing environmental impacts.
- SDG 13: Climate Action – Reducing carbon footprints by producing lightweight materials that contribute to energy savings.
- SDG 11: Sustainable Cities and Communities – Enabling cost-effective construction materials that support resilient urban development.
- SDG 8: Decent Work and Economic Growth – Driving industrial innovation that leads to new opportunities and economic benefits.
Future Perspectives
As industries continue to evolve, EconCore stands at the forefront with its continuous thermoplastic honeycomb production process. The integration of aerospace honeycomb technology with efficient production methods paves the way for a future where production is not only economical but also environmentally conscious… The innovation present in ThermHex technologies inspires confidence in a direction where materials are lighter, costs are lower, and the environmental impact is minimized. With such a dynamic process already in place for automotive, transportation, construction, and beyond, EconCore represents a forward-looking approach that aligns technological advancement with sustainable solutions. This visionary project continues to influence modern industry practices, shaping future material production with a blend of traditional engineering principles and contemporary technological strides.
