With more than 30 years of expertise in aerospace honeycomb manufacturing, we deliver high-performance solutions designed to meet the demanding requirements of gas turbine engines, aerostructures, and advanced industrial applications.
Honeycomb solutions
We provide lightweight honeycomb solutions, designed to enhance performance across applications.
Structural honeycomb
Our structural honeycomb is precision-engineered for aerospace applications where strength, durability, and weight optimisation are critical.
Manufactured in band form, with cutting or chamfering to exact customer specifications
- Commonly used in fan blade applications and other bonded aerospace components
- Available in stainless steel, nickel alloys, and titanium
- Proven applications include diffusion-bonded honeycomb for wide chord fan blades (e.g. Rolls-Royce Barnoldswick)
Abradable seals
We specialise in abradable honeycomb seals that provide highly effective, gas-impermeable sealing in the hot sections of engines.
- Cell sizes: 1.6–3.2 mm
- Foil thickness: 0.05–0.127 mm
- Depths: 5–14 mm
- Materials include stainless steel, Hastelloy X, Hayes 214, and other nickel alloys
- Components can be vacuum brazed to forged/cast rings or fabricated sheet metal assemblies
- Supplied in flexible formats: honeycomb only, individual segments, complete rings, or integrated assemblies
Acoustic honeycomb
Designed for noise attenuation and vibration reduction, our acoustic honeycomb plays a vital role in modern aero engine design.
- Available in corrugated wall honeycomb (welded band or manually assembled)
- Cell sizes: 9.5, 16, 19 mm
- Foil thickness: 0.05–0.127 mm
- Materials include stainless steel and titanium (including Beta 21S)
- Options include drain holes and vacuum-brazed assemblies
- Key applications: acoustic liners, exhaust cones, fan cowls (e.g. RR Tay, RR Spey, Aircelle)
Energy absorbers
Through our Darchem Honeycomb Products (DHP) division, we develop energy-absorbing honeycomb structures for safety-critical applications across multiple industries.
- Cell sizes: 3.2–38 mm
- Depths: 2–1250 mm
- Materials include stainless steel, titanium, mild steel, Hastelloy X, and Nimonics
- Crush strength range: 0.04–400 N/mm², with tight tolerance control (5–10%)
- Independently validated by UKAS-approved testing facilities
- Supplied in custom geometries: rectangular, round, angled, and profiled shapes
- Applications: rail safety, crane impact protection, nuclear energy absorbers
Flow conditioning devices
Flow straighteners
Ensure stable, laminar airflow by removing turbulence and angularity for optimal aerodynamic and fluid performance.
- Cell size: 1.6–38 mm
- Depth-to-cell ratio: 10–16
- Available in stainless steel, nickel alloys, and titanium
- Configurations: framed modules or homogeneous blocks
- Applications: wind tunnels, pipelines, marine exhausts, motorsport, oil & gas systems
Flow conditioning screens
Durable, woven stainless-steel screens engineered for precision airflow management.
- Tack-welded edges for strength
- Spring-loaded tensioners to prevent sagging
- Corrosion-resistant and easy to maintain
Turbulence Control Screens (TCS)
Specialist devices for aerospace engine testing, enabling realistic airflow conditions.
- Geodesic construction: 4–9 m diameter, aluminium/stainless steel honeycomb bonded to perforated skin
- Homogeneous construction: 2–4 m diameter, precision welded for zero frame blockage
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