Post by Axxor Group

PHC Myth #2: Paper honeycomb can only be used flat, it's a 2D material. Understandable assumption. Stacks of unexpanded honeycomb don't exactly scream "complex geometry." The reality: with the right approach, paper honeycomb can take on three-dimensional shapes. A few ways this works in practice: ◆ Stacking and bending: multiple layers combined in different orientations create 3D structures without any special tooling. ◆ Adding molded paper: integrating molded components into the stack opens up even more geometric freedom. ◆ Die-cutting with shaping: during production, extra forming can be built directly into the cutting process. ◆ Molding: during production, extra forming and adding the skins can be built directly into the pressing process. And there's something unique about paper honeycomb that makes this possible: local buckling. When pressure is applied during molding, the cells deform locally rather than failing all at once (global buckling). With the right combination of paper grade, cell size, and core height, you can shape honeycomb panels around curved surfaces, including tight radii like a small football. Myth busted. Want to explore what shapes are possible for your application? Our engineers are happy to think along.