3D printed sandwich cores

Sandwich cores are used in numerous applications. The advantages of honecomb, foam or balsa cores are well-known to industry: extremely high stiffness at very low mass. However, the cost of producing sandwich products in anything else than flat plate is very high and this is where our products come in.

Generally choosing a sandwich core material is a trade-off between density, shear- and through thickness properties and processing. With our printed cores this selection process is history; we can now optimise the core to the application!

Firstly, processing is no longer required. Generally core materials are milled, thermoformed or pressed into the right shape. All these processes are expensive and require expensive machines or tooling. We print the core directly into the required shape. The skins on the core are printed as well, so they are extremely suitable for use in our patented co-curing technology.

Secondly, by chaninging the orientation, amount and thickness of the reinforcing trusses inside the core, the shear and through thickness properties of the core can be fully optimised.

And lastly, we can now integrate functions. Any cable ducts, sensors, reservoirs, etc can be printed at once and don’t need to be drilled or fastened afterwards. This, again is a huge efficiency improvement compared to other sandwich construction.

Inspired by nature

Where honeycomb and especially truss structures are mostly what we use, we can also optimise further and use structures that are optimed by computer aided methods.


Most of our customers at first have the idea that printed cores are way to expensive. In most cases (when it comes to technical cores), we have proven to be able to be very competitive when the total production costs are considered.

The internal structure can be modified and optimised to ensure maximum part performance: where loads are high a more dense internal structure is used and where loads are low, internal mass can be minimised.

Integration of cable ducts, sensor layouts or internal spaces for electronics; it can all be combined in the printed core, resulting in much less assembly.

The printed core can be produced in the required dimensions, saving enourmous efforts compared to milled or thermoformed cores, whilst performance is equivalent.

The number of options with respect to our core materials are enormous; e.g. structure, angles, amount of bars, thickness of bars, etc can be varied. This means we typically work with our customer to find the best core setup. If required by our customer, we can perform mechanical testing data for comarison to alternative core materials, but we prefer to do that on the actual product.

Jasper BouwmeesterSandwich cores