PP Honeycomb Cutting

Trade-grade PP honeycomb cutting for lightweight, rigid panels used in signage, displays, construction and industrial applications. We use high-precision CNC router and digital knife cutting to process polypropylene honeycomb panels from one-offs to large production runs. PP honeycomb offers an excellent stiffness-to-weight ratio — ideal where weight, strength and recyclability matter.

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Flat parts only — no folding Typical sheet up to 3000 × 1500 mm 1–5 days dispatch

Industries we work with for PP honeycomb

We cut polypropylene honeycomb panels for a wide range of industries that need lightweight, rigid and durable sheet materials. Flat parts only — no forming in-house. CNC router and digital knife cutting provide clean edges and accurate profiles, ready to assemble or bond with other components.

Signage & Display
Large format panels, hanging signs and backers for printed skins.

Exhibitions & Events
Modular wall panels, plinths, fascia boards and set elements.

Construction & Fitout
Lightweight wall infills, ceiling panels and partition elements.

Retail & POS
Freestanding displays, totems and structural cores for retail fixtures.

Transport & Logistics
Pallet tops, liners and lightweight crates (panel cutting only).

Industrial & Packaging
Dunnage, dividers and protective inserts using honeycomb cores.

PP honeycomb thickness guide

PP honeycomb is a lightweight polypropylene core bonded to skins (often polypropylene, aluminium or printed laminates). The table below reflects typical thicknesses we encounter in signage, events and industrial work. Exact availability depends on the panel system, skin type and supplier, and can be confirmed when quoting.

Working ranges for common honeycomb panels

PP honeycomb thickness	Typical use
5–8 mm PP honeycomb	Lightweight panels for small displays, inserts and packaging elements.
10–12 mm PP honeycomb	Common thickness for signage backers, exhibition panels and POS structures.
15–20 mm PP honeycomb	Heavier-duty wall panels, plinths, fascias and structural display elements.
Above 20 mm PP honeycomb	Specialised structural or industrial panels (job-dependent, confirm in advance).

*Thickness ranges above are indicative for PP honeycomb panels used in signage, events, construction and industrial work. If you are supplying a proprietary panel system, include product data so we can confirm the most suitable cutting method and tooling.

Capabilities at a Glance — PP Honeycomb

Processes & Materials

CNC router cutting of PP honeycomb panels
Digital knife cutting for certain panel types and thinner honeycomb boards
Straight cuts, complex shapes, slots, cut-outs and radiused corners
Drilling and basic machining for fixings and hardware
Panels supplied by you or sourced via our network (job-dependent)

Typical Part Types

Wall and ceiling panels — events, interiors, exhibitions
Display structures & plinths — POS, retail, brand activations
Liners, tops & cores — transport and industrial use

Accuracy

Router and knife cutting tuned for lightweight core panels
Dimensional tolerance suitable for modular systems and repeat builds
Repeatability ideal for multi-panel sets and ongoing campaigns

Finish

Clean cut edges with minimal tearing or crushed cells
Optional rounding of corners and deburring for improved handling
Compatible with many printed skins, laminates and edge treatments (done by others)

Sheet Size

PP honeycomb panels are typically supplied in large-format sheet sizes, ideal for exhibitions and construction. Our cutting beds are sized for full boards, with efficient nesting to minimise waste and keep unit costs down across one-off projects and full campaigns.

We focus on flat PP honeycomb panel cutting. If panels will be edge-capped, bonded to printed skins or assembled into larger structures, we can cut the flat components, mark features and help with packing them logically for install.

Why use our PP honeycomb cutting service?

Set up for lightweight panel systems

We work with lightweight PP honeycomb panels regularly for signage, exhibitions and construction projects. Toolpaths, feeds and nesting are tuned specifically for core panels to avoid tearing and deliver clean, accurate edges.

Production-friendly for campaigns and rollouts

Once we have your panel sizes, cut-outs and fixing details dialled in, we can support regular rollouts and repeat builds with predictable pricing, timing and packing — ideal for national fitouts and campaign refreshes.

Integration with printed and fabricated elements

PP honeycomb panels are often combined with printed skins or additional fabrication. We can work from your drawings or artwork and help ensure that cut-outs, fixings and panel sizes align with other trades such as printers, joiners or builders.

Trade-ready workflow

Clear specs on panel type, thickness, edge requirements, hole positions and tolerances, plus realistic lead times and consistent re-runs. Our workflow is designed for trade clients, fabricators and agencies who need dependable outcomes on PP honeycomb jobs.

Sydney-based, Australia-wide

Production in Botany NSW with national shipping — suited to local exhibition builds, multi-site rollouts and ongoing programs using PP honeycomb systems.

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Get instant prices for laser-cut and CNC-cut parts across metals, plastics, composites and more — available 24/7.

1–5 days dispatch Australia-wide delivery Pickup: Botany NSW

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Launch the calculator to upload DXF, DWG or vector files and see live pricing for flat laser-cut parts. Pricing updates instantly based on material, thickness and cut time.

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Accepted formats: DXF / DWG / AI / SVG / PDF (vector).

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Send measurements, sketches or existing parts and we’ll create cut-ready drawings, then quote via the same engine.

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Simple plates and brackets can often be drawn and quoted the same day.

More about PP honeycomb cutting & lightweight panels

Open the items below for more detail on PP honeycomb cutting, design tips and how PP honeycomb compares with other lightweight materials for signage, events and construction.

For PP honeycomb panel designs, confirm fixing details, joint locations and edge treatments early. Allow for router tool diameter on internal corners, avoid tiny unsupported tabs, and keep panel sizes compatible with transport and site access. If panels will receive printed skins, confirm bleed and wrap details with your printer so cutting lines and artwork align.

PP honeycomb offers an excellent balance of weight, stiffness and durability, making it a strong option versus solid plastics, plywood or MDF where weight is critical. For smaller signs or where a very smooth printed face is needed, ACM, acrylic or foam PVC may be preferable. We can help compare options based on weight limits, fire performance and budget.

PP honeycomb panels are light but often large. We typically stack and wrap panels, then pack in cartons or on pallets depending on size and quantity. If jobs are for multiple sites, we can bundle and label panels to match your distribution plan so each location receives exactly what they need.

Most PP honeycomb cutting jobs dispatch in 1–5 business days once artwork, panel specs and quantities are confirmed. Larger campaigns, multi-site projects or complex assemblies may take longer, but we will confirm realistic timeframes before you commit.

DXF/DWG preferred; AI/SVG/PDF (vector) accepted. Units in mm; include fixing positions. Upload via the instant quote.

Whether you need a handful of PP honeycomb display panels or a full national rollout of lightweight wall and ceiling panels, our CNC router and digital knife workflow is set up for trade-ready results and predictable lead times. Upload your files or contact us to plan your next PP honeycomb project.

Typical applications include exhibition displays, event signage, retail displays, ceiling panels, wall cladding and lightweight partitions. We work with exhibition builders, event companies, shopfitters and interior designers across commercial projects.

Excellent weight-to-stiffness ratio for large format panels.
CNC routing for clean edges and accurate panel dimensions.
Optional coordination with printers for skin application.

For PP honeycomb cutting that delivers lightweight, rigid panels ready for exhibition, event or fitout installation, upload your files or contact us to discuss panel specifications and project requirements.