Why Machining Non-Metallic Honeycomb Composites Is Harder than It Looks

Honeycomb composites are named for their structural resemblance to honeycombs. As composites, these materials are artificially fabricated, created by combining two or more base materials. Non-metallic honeycomb composites refer to honeycomb materials made primarily from fibers or plastic polymers rather than metals. While their honeycomb structure appears straightforward, the combination of materials and internal geometries makes honeycomb machining more difficult than expected.

Here, we explore why honeycomb composites seem simple at first glance, but actually present unique machining challenges. Keep reading to learn more. Contact us for more information.

What Are Honeycomb Composites?

Honeycomb composites are materials with a lightweight, honeycomb-like geometry: hexagonal, beehive-shaped cells. These materials are often bonded with face sheets to create durable sheets or panels. Common types of non-metallic honeycomb composites include Nomex, fiberglass, and aramid cores.

Honeycomb composites are popular for OEM applications across industries such as aerospace, defense, transportation, and industrial manufacturing due to their high strength-to-weight ratio, energy-absorption properties, and stiffness. The honeycomb lattice provides high compression and shear properties while maintaining a low density.

Why Are Honeycomb Composites Difficult to Machine?

While honeycomb composites are desirable for their many advantageous properties, those same traits can also make machining challenging. Their complex geometry requires specialized machining processes and substantial post-processing to achieve precision.

Honeycomb composites are strong. Their fundamental structure, however, is very delicate. The honeycomb cells can be easily damaged during CNC machining. Achieving precision requires trained operators, specialized equipment, and dedicated time.

Common Mistakes Engineers & OEMs Make When Machining Honeycomb Composites

Honeycomb composite machining may appear to be a simple process, but looks can be deceiving. Uninformed operations can lead to mistakes. Common assumptions include:

• Assuming standard CNC machining processes will work
• Underestimating fixturing and support requirements
• Choosing incorrect tooling or speeds/feeds
• Not accounting for secondary finishing needs

Neglecting the proper handling and strategies for honeycomb composite machining can result in poor edge quality, structural damage, dimensional inaccuracies, and increased material waste.

Best Practices for Machining Honeycomb Composites

While honeycomb composite machining can be challenging, following these best practices can help achieve high-quality results:

• Cutting method: Choosing the right cutting method is the key to achieving precision results. CNC milling, 5-axis machining, and CNC turning equipment are ideal for machining honeycomb composites.
• Sharp tooling: Sharp tools are essential for precision cuts and protecting the structural integrity of honeycomb composites.
• Speed: When machining honeycomb composites, speed is everything. Slow machining can push the material away, leading to uneven cutting and inaccurate dimensions. High RPMs (around 30,000) ensure shearing, rather than pushing.
• High feed rates: Heat buildup can damage composite materials. High feed rates (around 0.076mm per tooth) reduce heat buildup and protect components during machining.

How Upland Fab Solves Machining Challenges

At Upland Fab, we have extensive experience machining complex components from a range of materials, including non-metallic honeycomb composites. We understand how to handle the delicate honeycomb structure without damage, and we use advanced machining techniques to maintain dimensional accuracy and ensure precision every time. By using sharp tools at high feed rates and speeds, we achieve clean cuts and consistent results that meet your specifications.

Contact Upland Fab Today

Producing complex, precision components from honeycomb composites takes the skills and knowledge of an experienced machining expert. At Upland Fab, we have decades of machining experience, creating custom solutions for a variety of applications and industries. We partner with engineers and OEMs to deliver custom solutions for complex projects. Our ISO 9001:2015 and AS9100 Rev D certifications demonstrate our commitment to quality and our adherence to industry standards. We are dedicated to providing excellent customer service and results you can count on.

Contact us with any questions or to learn more. Request a quote to begin your project today!