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Production Process of Aramid Honeycomb Core

The manufacturing of aramid honeycomb core involves a highly controlled, multi-stage process to ensure optimal mechanical properties and structural integrity. Below is a detailed technical description of the production steps:

1. Raw Material Preparation

Aramid Fiber Paper: Sheets of meta-aramid (e.g., Nomex®) or para-aramid fiber paper are used as the base material.
Resin Impregnation: The paper is coated with a thermosetting resin (typically phenolic, polyimide, or occasionally epoxy) to enhance rigidity and heat resistance.

2. Lamination (Stacking & Bonding)

Adhesive Application: Alternate layers of resin-coated aramid paper are bonded with controlled adhesive lines (usually a reactive thermoplastic film or resin).
Curing: The stacked sheets undergo moderate heat (~120–150°C) and pressure to partially cure the resin, forming a solid block.

3. Slitting
Cross-Cutting: The laminated block is precision-cut into slices of the desired honeycomb thickness using CNC machines or diamond-edged blades.

4. Expansion
Mechanical Stretching: Each sliced block is expanded under controlled tension (manually or via machinery) to stretch the adhesive bonds into uniform hexagonal cells.
Cell Geometry: Cell size (5–20 mm) and density (24–144 kg/m³) are determined by the expansion ratio and resin content.

5. Final Curing
Oven Treatment: The expanded honeycomb is heat-treated (~150–200°C) to fully cure the resin, locking the hexagonal structure and maximizing mechanical stability.

6. Post-Processing (Optional)
Resin Overcoating: Additional resin may be applied for enhanced moisture/fire resistance.
Surface Machining: CNC trimming or waterjet cutting ensures dimensional accuracy for specific applications (e.g., aerospace panels).