Aluminium Honeycomb Panels From Aludecor Powered By In-house Honeycomb Core Manufacturing
When envisioning the buildings of tomorrow, both beauty and performance are crucial. With the rise in demand for stronger, lighter, and more innovative facade solutions, Aludecor’s Nexcomb aluminium honeycomb panels stand apart as a game-changing product that combines advanced engineering with design versatility. Here’s why Nexcomb is setting new benchmarks in the architectural landscape and why it should be a preferred choice for cutting-edge facades.
The Unmatched Strength of Hexagonal Engineering
The core strength of Nexcomb lies in its honeycomb structure: nature’s own marvel adopted by modern engineering. The hexagon, as seen in beehives, is scientifically the strongest natural structure. When applied to aluminum honeycomb panels, this design translates into:
- Maximum Strength-to-Weight Ratio: The ingenious distribution of material ensures Nexcomb aluminium honeycomb panels are impressively rigid yet remarkably lightweight. This ratio outperforms even standard aluminium composite panels, making Nexcomb ideal for applications facing high wind load or structural constraints
- High Wind Pressure Resistance: Honeycomb facades can withstand the highest wind speeds, making them perfect for tall buildings and critical infrastructure
- Multi-Application Versatility: Beyond façades, aluminium honeycomb panels are widely used in bus floors, railway coach floors, escalators, elevators, and other applications that demand robust yet lightweight solutions
- Custom Load-Bearing Capability: Smaller cell sizes (as little as 6mm) provide increased load-bearing capacity, making the panels adaptable to varied project needs
Five Reasons Why Nexcomb Aluminium Honeycomb Panels from India Should Be Your First Choice
1. Unrivalled Strength and Wind Resistance
The honeycomb core design of Nexcomb gives it exceptional strength-to-weight performance. Its hexagonal cells act like countless miniature I-beams, absorbing and distributing stress more efficiently than any other panel structure. This ensures facades made with Nexcomb effortlessly withstand wind pressures and impact, even in the most challenging environments.
2. Ultra-Lightweight Construction
Nexcomb is lighter than even traditional aluminium composite panels. The dramatic reduction in dead load not only simplifies installation but also lowers the structural demands on the building itself, leading to greater design freedom and potential cost savings.
3. Precision Engineering via Automated Manufacturing
Aludecor’s state-of-the-art automated manufacturing processes guarantee tight tolerances, flawless assembly, and consistent quality in every panel – features that directly impact the panel performance and long-term reliability. This high degree of precision is unparalleled in the Indian ACP market.
4. Innovative and Custom Finishes
As a pioneer of coil coating lines in India – at present having 3 state-of-the-art CCLs with one triple-coat-double-bake line – Aludecor delivers a vast palette of innovative finishes. Whether you seek Timber, Rustic, Sand, Pedra, Concrete-Finish, Earth Coat etc., Nexcomb can be tailored to your creative vision subject to MOQ.
5. Panel Thickness Flexibility
Nexcomb panels are available from 6mm all the way up to 100mm in thickness, enabling you to select exactly what your project demand whether it’s a slender partition or a robust, load-bearing facade.
Inside the Nexcomb Automated Manufacturing Process
What sets Nexcomb Aluminium Honeycomb Panels from India apart is its end-to-end in-house capability combined with superior automation:
Premium Raw Materials: Aludecor uses Hindalco aluminium coils, which undergo pretreatment for corrosion resistance, followed by precision cut-to-length as per project requirements
Automated Tray Formation: Advanced roll forming machines produce trays in exact sizes for superior fit and finish
Honeycomb Core (Nexcore) Production:
- Aluminium foils are coated with glue in a special sequence and partially cured for optimal bonding
- Sheets are precisely stacked with glue strips alternately aligned to avoid overlap, ensuring homogenous strength distribution
- Slices for the honeycomb core are cut using automated sawing for exact thickness (e.g., for a 12mm panel with tray skins of 0.7mm and 0.5mm, the core is cut to 10.8mm)
- In the core expanding machine, foils are stretched into perfect hexagonal cells. Custom cell sizes (6mm, 10mm, 14mm, 19mm) offer tailored strength and weight profiles
Assembly and Bonding: The panels are manually assembled and bonded using automated glue application, followed by hot-pressing at 80°C for 15–20 minutes. This ensures uniform adhesion, panel thickness, and defect-free results.
Coil Coating: In-house coil coating lines provide the ability to offer a range of finishes unmatched in the industry
Design Flexibility: Bent and Curved Panels
Nexcomb’s versatility extends to curved applications. The aluminium honeycomb panels can be moulded into radii from 300mm up to 2,000mm, perfect for airport pillars, bullnoses, and other architectural features where sleek, flowing lines are essential.
Why In-House Honeycomb Core Manufacturing Matters
Aludecor is the only Indian ACP company among aluminium honeycomb core manufacturers in India. This means:
- Superior Quality Control: From foil to finished aluminium honeycomb panels, every step is tightly monitored, ensuring consistent quality and faster turnaround
- Customization: Quick adaptation to unique project needs, whether that’s a rare size, custom cell, or special finish
- Reliability: Supply chain independence and full traceability deliver peace of mind to architects, contractors, and end users alike
Where and Why to Use Aluminium Honeycomb Panels
Aluminium honeycomb panels like Nexcomb are ideal for:
- High-rise facades where wind resistance and low weight are priorities
- Transportation infrastructure: bus and railway floors for lightweight durability
- High-traffic floors in malls, airports, and commercial buildings
- Elevator and escalator components requiring strength with minimal bulk
- Architectural features – curved or bent panels for bold design statements
Smaller cell sizes are particularly suited for areas with high load requirements, while larger panels maximize coverage and minimize joins for a sleeker appearance.
Engineering Tested, Quality Assured
Every Nexcomb panel passes through a series of tests meeting the highest international standards (ASTM, ISO). Routine assessments include:
- Tensile strength
- Shear properties
- Flatwise and edgewise compressive strength
- Peel strength and flexibility
- Weatherability and fire safety
Sourcing premium materials (aluminium from Hindalco, adhesives from Henkel/Sika), combined with advanced production and testing, means every Nexcomb panel is built for performance and longevity.
Tomorrow belongs to Nexcomb
For architects, engineers, builders, and regulatory bodies looking for a facade solution that delivers not just aesthetics but also unparalleled structural performance, Nexcomb by Aludecor is the definitive answer. In fact, Nexcomb aluminium honeycomb panels’ price per square feet is well worth paying for.
Choose Nexcomb for:
- Best-in-class strength-to-weight ratio
- Lightest dead load among facade panels
- Flawless surface quality and innovative finishes
- Total design freedom: flat, curved, or custom
- Reliability and traceability through in-house manufacturing
Contact Aludecor’s team today to discover how Nexcomb can elevate your next project with tomorrow’s technology, today.
