These carbon fibre sandwich panels are produced by Juno Composites using our proprietary α-FAB liquid moulding technology. Unlike traditional composite manufacturing methods, α-FAB is an advanced closed-mould process that increases productivity, delivers higher laminate quality, improves mechanical performance, and reduces unit cost. The result is a superior carbon fibre sandwich construction that outperforms conventional autoclave and standard resin-infusion methods. All panels are manufactured under our ISO 9001-certified quality management system to ensure consistent, repeatable high quality. You can also design and configure your own custom sandwich panels using our online JunoPanel Designer tool.
Each panel is built around a lightweight 5 mm Divinycell H45 PVC foam core (nominal density ≈ 45 kg/m³) and reinforced on both sides with a single ply of 2×2 twill carbon fibre fabric, available in either 3k or 12k weave. The foam core provides excellent shear stiffness and compressive support, while the carbon skins deliver high in-plane strength, bending stiffness, and a durable, stable surface. This combination offers an outstanding stiffness-to-weight ratio and reliable long-term performance under load.
Designed for demanding engineering applications, these sandwich panels can be CNC-machined into precision components or used directly as lightweight structural panels in motorsport, aerospace, UAV, marine, and industrial composite structures where weight saving, stiffness, and dimensional stability are critical.
Integrated hardpoints & solid laminate inserts
Juno Composites can incorporate fully integrated carbon fibre hardpoints and solid laminate inserts within these sandwich panels, allowing high-strength mounting and load-introduction areas to be created directly during manufacture. Using our α-FAB liquid moulding process, these reinforced zones are positioned exactly where loads will be introduced and consolidated seamlessly into the surrounding sandwich construction.
Unlike bonded-on inserts, patches, or core-potting, this integrated approach produces a single unified laminate with smooth transitions and a clean, professional appearance. The panel remains extremely lightweight, with localised strengthening built in only where the structure needs it, ensuring efficient load transfer without unnecessary mass. Hardpoints are positioned using Juno’s structural engineering expertise and in-house process knowledge. For applications such as automotive floor panels, UAV structures, marine interiors, industrial enclosures, and robotics systems, we can integrate mounting clusters, hinge pads, bolt interfaces, or jacking-point regions during the moulding stage and then CNC-profile the finished panel to its final geometry. Customers receive a ready-to-install lightweight component engineered around their specific requirements. For custom engineering support or a quotation, please contact info@junocomposites.com.
Surface Finish
All panels are supplied as standard with a C/C surface finish, featuring a Class C moulded smooth tool face on both sides. These are structural-grade surfaces defined by function rather than appearance; the moulded faces are smooth and functional but are not intended as cosmetic or decorative finishes. This C/C finish is ideal where panels will be painted, bonded, skinned, or installed in applications where performance and weight are prioritised over visual perfection. Other finishes may be available upon request.
Ideal uses include
- Lightweight motorsport body panels, undertrays, interior panels, and fairings
- Automotive floor panels, closures, access hatches, and structural covers
- UAV wingskins, fuselage panels, equipment bays, partitions, and housings
- Marine interior panels, bulkheads, furniture modules, and non-slamming structures
- Robotics and machinery: lightweight guards, sensor housings, EOAT frames, and enclosures
- Product design and industrial applications: stiff backing panels, display and exhibition structures, composite furniture
- CNC-machined sandwich components requiring high bending stiffness at very low mass
- Acoustic and vibration-damping panels benefiting from the foam core’s damping characteristics
Key features
- Manufactured using Juno’s proprietary α-FAB liquid moulding technology
- 5 mm Divinycell H45 PVC foam core for excellent stiffness-to-weight performance (nominal core density ≈ 45 kg/m³)
- Single-ply 3k or 12k 2×2 twill carbon fibre skins on both faces
- 3k 2×2 twill skins (0.2mm each side) total panel thickness= 5.4mm thick and ~ 1.7kg/m²
- 12k 2×2 twill skins (0.57mm each side) total panel thickness= 6.1mm thick and ~ 2.85kg/m²
- Lightweight sandwich construction with localised strengthening only where required
- Fully integrated hardpoints and solid laminate inserts available as a custom option
- CNC machinable with clean edges, precise apertures, and accurate profiling
- Produced under an ISO 9001-certified quality management system
- High-quality, void-free laminates with consistent mechanical performance
- Standard C/C surface finish (smooth moulded Class C tool face on both sides)
- Standard glass-transition temperature (Tg) 80 °C; higher-Tg systems available on request
- Custom sizes, core options, layups, and machined profiles available on request
- Full technical datasheet available
Surface Finish Classes
These are structural-grade laminates, not cosmetic. The surface finish is defined by function, not appearance:
- Class A – Smooth, glossy, nearly flawless finish for visually demanding parts
- Class B – Peel-ply textured surface for bonding
- Class C – Moulded smooth tool surface (functional, not decorative)
- Class D – Smooth textured face, hygienic and washable
For more information, see our Surface Finish FAQ.
Note: All surface finishes should be protected with a suitable UV-stable coating if the part will be exposed to sunlight.
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