The EconCore lightweight honeycomb enables the Renolit Gorcell product line to overcome technical challenges and promote the application range of automotive and other markets such as furniture and gardens.

Image source: EconCore, Renolit SE

Honeycomb technology company EconCore (Leuven, Belgium) and Renolit SE (Rhineland-Palatinate, Germany) collaborate to explore lightweight, modular design, easy formability and rigidity for the automotive industry and other markets through EconCore's polypropylene (PP) Various problems with the structure of the honeycomb core. Through this cooperation, Renolit also seeks to improve chemical, thermal, waterproof and anti-corrosion properties.

Renolit's R&D team obtained EconCore's continuous production license for honeycomb panels and applied EconCore's honeycombs to its Gorcell product line. The honeycomb sandwich layer combines a composite skin with a hexagonal honeycomb structure and is currently used not only in automotive applications such as truck superstructures, but also in aviation boxes, outdoor kitchens, and bakery panels. Recently, Renolit has been selling products for gardens, balconies and terraces, such as tissue boxes, plants, high beets and fences, to the B2C market through its subsidiaries. 

Renolit Composites Sales and Marketing Director Axel Kulke said: "When we need to create lightweight solutions, EconCore's cellular technology is really great for us, and these solutions look great for a variety of applications. "The impact on the surface properties is shocking."

After years of developing this technology to meet the specifications required by the market, EconCore's honeycomb enables Renolit Gorcell to overcome a number of technical challenges, such as panel flatness, reduction of golf effects and smooth, scratch-free surfaces. According to Renolit, compared with other standard materials on the market, its Gorcell series offers additional advantages, such as special decorative surfaces, while meeting the requirements for lightweight and technical performance.

In addition, according to reports, in addition to improving physical properties, honeycombs also have commercial benefits. If continuous extrusion is used, this advantage can be fully utilized. Renolit Gorcell's production process currently includes film unwinding, vacuum forming, core calibration, surface layer lamination, panel calibration and cutting.

Renolit said that the next steps include optimizing the production line to further improve process efficiency and exploring new applications.

"Using a continuous manufacturing process, we have been able to supply products to Europe and have projects spanning other parts of the world. Having strong and lightweight products is exactly what we are creating diversified products such as storage boxes, furniture, RV construction and car interiors. You need it at the time. Renolit Gorcell has this versatility," Kulke added.

The partnership also advances the green agenda of the two companies. Renolit is a member of the Recycling Plastics Alliance and has made commitments in accordance with the European Plastics Strategy of the European Union. The strategy aims to increase the use of recycled plastics to 10 million tons by 2025. This strategy resonates strongly with EconCore's commitment to sustainability through its cellular technology. 

Bianka Nagy, Marketing Communications Manager at EconCore, said: “The collaboration with Renolit shows that our cellular technology provides a range of benefits in a wide range of applications. They really accepted it, ran it and pushed it to areas we couldn’t imagine. We look forward to continuing this pioneering work with Renolit in many industries such as automobiles, caravans, outdoor and garden or beach furniture manufacturing."

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