Comprehensively analyze the high difficulty manufacturing of curved honeycomb panels from four aspects

The production and manufacturing process of honeycomb panels is quite complex, especially for curved honeycomb panels, which are extremely difficult to manufacture and can be a headache.

Next, I will explain to you why the manufacturing difficulty of curved honeycomb panels is so high from the following four key aspects?

1. Design accuracy

Due to its planar structure, the design parameters of conventional honeycomb panels mainly focus on size, thickness, and honeycomb core specifications.

Due to its unique curved shape, the curved honeycomb panel requires precise calculation of the parameters for each arc. Designers need to accurately determine parameters such as the radius, central angle, and arc length of the arc according to the requirements of the usage scenario.

These parameters not only affect the appearance of the curved honeycomb panel, but also directly affect the subsequent installation and splicing.

2. Mold making

Mold is the core tool for producing curved honeycomb panels, and the difficulty of mold production is extremely high.

To produce curved molds that meet design requirements, high-precision processing equipment and exquisite craftsmanship are required.

The curvature of the mold must be completely consistent with the design requirements, and the error must be controlled within a very small range.

And the material selection of the mold is also very particular, ensuring sufficient strength and stability to withstand the pressure during the production process, while considering its impact on the surface quality of the curved honeycomb board to ensure the smoothness of the honeycomb board surface.

In contrast, the mold production of conventional honeycomb flat panels is much simpler, and the production process of flat molds is already quite mature, with less stringent requirements for accuracy than curved molds.

3. Forming process

In the forming process of curved honeycomb panels, it is necessary to ensure that the honeycomb core material and the panel are bent synchronously without wrinkles, cracks, deformation of the honeycomb core, and other problems. This requires precise control of multiple parameters such as bending force, speed, and angle.

However, different materials and honeycomb structures have significantly different requirements for bending processes, which requires extensive experimentation and experience accumulation to determine the optimal molding process parameters. For example, for thicker honeycomb panels or smaller radius arcs, the difficulty of forming will significantly increase.

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4. Quality Inspection and Control

Due to the presence of arcs, traditional methods and tools for plane detection often fail to meet the requirements.

For the detection of quality indicators such as curvature, dimensional accuracy, and surface flatness of curved honeycomb panels, special measuring tools and methods are required. These devices are expensive and require professional technicians for operation and data analysis.

Moreover, in terms of quality control, curved honeycomb panels are more prone to local deformation and uneven thickness during the manufacturing process. These problems are difficult to detect and repair, and require a stricter quality control system and professional technical personnel to ensure product quality.

Meanwhile, as curved honeycomb panels are usually customized products, the production parameters of each batch may vary, which puts higher demands on the quality control system.