A thin core material to replace balsa?

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#1

Hello new member here. I am working on some small airplane parts for work. currently it uses balsa as a core material. My layup is 2 layers of carbon, a layer of 1/16th balsa, and two layers of carbon a 1k 3.5 oz cloth. I have some very curved surfaces on some of the parts and was wondering if there was core similar to balsa in lightness and strength that would be easier to place in a compound curve? Right now I am piecing together small slivers of balsa to go around a dome shaped part. Is there a foam core that is available that is that thin? Thanks

Curly

#2

3mm expanded honeycomb core works well, however I wouldnt suggest using it unless its with prepreg. Its very difficult to get a really good bond with out the use of film adhesive despite what people may say. You also would probably have to do a double cure, first cure to mold the core in to shape, second to laminate the back. You may be able to heat form foam core depending on how compounded your shape is. However that requires a additional step as well to preform the core. Lastly would be a lantor coric core mat, however they absorb a lot of resin.

#3

The 3M core can I get it as thin as 1/16th of an inch (.0625)? Thanks for the info much apprciated.

#4

The thinest I have ever seen for honeycomb core is 3mm (1/8"). Lantor Soric has the TF core at 1.5mm (1/16"), they may have another version aswell. But depending how compounded the shape is you may need to put relieve cuts in the core.

#5

I’ve used a new product from Soric called LRC in the 2mm thickness that under full vacum will get close the final thickness you’re looking for. They also have a 1.5mm version. It also conforms really well.

Actually surprising light - better then previous Soric stuff.

#6

i have some pretty decent experience core forming balsa. soaking the balsa in hot water then bagging over mold. it take some time figuring out how long to soak before its ready.

place a lamp or heat pad over the bag and then perform water extraction… can take 24- 48 hours. trim balsa and use.

ive seen 1/8 balsa formed into a nose cone for a r&d radome core. granted it wasnt used as a radome it was used for rcs purposes…

#7

Wow thanks guys this is some great info. I will look into all of these suggestions. Much appreciated.

#8

where did you source your soric lrc? and does this source sell smaller quantities?

#9

Good idea, thanks for that info!! I will try to remember that if I need to do something crazy :slight_smile: