Inserts in sandwich panels

With inserts, your sandwich panel can be customized to meet your specific requirements. For example, you can incorporate mounting structures or reinforcements wherever your situation requires them.

Sandwich panels consist of thin outer layers and a comparatively lightweight core. This gives them high flexural stiffness combined with low weight. Reinforcing layers are a major strength of our product portfolio. Our discontinuous production process gives us complete flexibility, allowing us to incorporate the reinforcements exactly where they are needed.
With our “ Corapan ” product line, the core is manufactured, the reinforcements are incorporated, and the core is bonded to the face sheets—all in a single step. This eliminates the need for the conventional milling of the core and gluing of the reinforcements. This process is efficient and results in the best possible bond between the core material and the reinforcements.

Inserts serve as
Reinforcements
Mounting points
Fasteners
Cable channels, locking mechanisms, etc.

Typical Applications Using Inserts

Inserts are frequently used in wall, roof, and floor panels in vehicle and container construction. In floors, they are used to secure the superstructure to the substructure or subframe. In walls and roofs, aluminum flat profiles are often used as a fixing structure for installing interior fittings.

At Coratec , many of these elements are integrated during the manufacturing of the sandwich panels. This results in robust, durable composite panels that are precisely tailored to mechanical, functional, or aesthetic requirements.

Mounting points
Inserts often serve as a load-bearing structure for components such as:
Hinges
Locks
Gas Springs
Eyelets or Mounts
Without inserts, these components would be attached only to the thin facing and could come loose or tear out.

Integrating Channels: Inserts can be used to create channels in the sandwich composite panels, for example, to route cable harnesses.

Inserts in panels with a Corapan core

In sandwich panels with a " Corapan" core, reinforcements are integrated directly during the core’s manufacturing process. The core is introduced in a free-flowing state during the manufacturing process and then compressed. Reinforcements can be integrated directly into the core during this process.

Advantages of this method:
The usual preliminary milling of the core is no longer necessary
highly efficient production
Optimal bond between the core material and the insert
Typical inserts:
Flat Aluminum Profiles
Aluminum F-Profiles
Aluminum U-Profiles
Round tubes made of aluminum or plastic

Limitations regarding Corapan

Because the core is compressed during manufacturing, inserts with a large height cannot be integrated. In particular, inserts that extend from facing to facing cannot be used in Corapan cores.

Inserts for Prefabricated Cores

For sandwich panels with prefabricated core materials (e.g., PET, PUR, or XPS), the negative mold of the insert is first milled into the core. The insert, core, and face layers are then bonded together and pressed. This process allows for greater design flexibility in the geometry of the inserts.

Possible materials:
Aluminum
Steel
adhesive-bondable plastics
High-density rigid foams (e.g., PET or PUR)
Typical geometries:
Flat profiles
Rectangular Tubes
Solid material
Plates

Inserts in sandwich panels

Inserts serve as

Typical Applications Using Inserts

Mounting points

Inserts in panels with a Corapan core

Advantages of this method:

Typical inserts:

Limitations regarding Corapan

Inserts for Prefabricated Cores

Possible materials:

Typical geometries:

Additional Finishing Options

Send us your plans—we'll assess their feasibility and provide an estimated completion date.