Lightweight, rigid and rot-proof composite solutions to optimise RV performance
In the world of motorhomes, caravans, camper vans and pick-up cells, every kilogram saved improves payload capacity, reduces fuel consumption and increases overall vehicle durability.
Nidaplast® honeycomb sandwich panels have become a benchmark for manufacturers and industrial bodybuilders thanks to their unique combination of lightweight construction, stiffness and moisture resistance.
Why use Nidaplast® honeycomb panels in recreational vehicles?
Thanks to their extruded polypropylene honeycomb core, they offer:
- very low surface density (≈ 65 kg/m³), ideal for reducing structural weight,
- exceptional stiffness through efficient skin-to-core coupling,
- total rot resistance, even in cases of infiltration or condensation,
- high mechanical performance for technical floors and stressed walls,
- excellent compatibility with composite processes: polyester, epoxy, vinylester, infusion, RTM, structural bonding.
Performance requirements in the recreational vehicle sector
Major structural weight reduction
The very low density of the honeycomb core enables 25–40% weight savings compared to traditional plywood panels.
Benefits:
- increased payload capacity,
- reduced fuel or electrical consumption,
- improved driving range,
- easier compliance with PTAC / GVWR limits.
Stiffness and mechanical behaviour of sandwich panels
Nidaplast® honeycomb cores provide excellent:
- compressive strength,
- shear strength,
- dimensional stability,
- puncture resistance for floors.
They ensure stable mechanical performance over time, even under repeated loading.
Rot-proof behaviour & moisture resistance
Unlike plywood, polypropylene:
- does not absorb water,
- does not swell,
- does not deform,
- does not rot.
The panel maintains its geometry, stiffness and mechanical integrity throughout the vehicle’s service life.
Acoustic & thermal comfort
Thanks to the viscoelastic properties of polypropylene, Nidaplast® cores provide:
- natural vibration damping,
- reduced road and engine noise,
- improved interior comfort.
Ease of processing
Nidaplast® panels:
- are easy to cut (CNC, circular saw…),
- can integrate inserts (wood, PU, aluminium…),
- are thermoformable,
- adapt to the curved shapes of modern RV layouts.
Typical applications of Nidaplast® panels in recreational vehicles
Structural applications
Cell floors
Technical double floors
Storage compartment floors & liners
Lightweight vertical partitions
Composite technical walls
Modules & interior RV furniture
Technical doors and hatches
Worktops and table tops (as cited by specialised press)
Lightweight furniture (cabinets, storage modules)
Decorative interior panels
External / peripheral components
Bay covers
Casings & prefabricated modules
Technical housings & secondary panels
Press coverage: example from Le Monde du Camping-Car
The magazine highlights the advantages of Nidaplast® honeycomb in sandwich panels:
“The surface mass of a honeycomb panel, with a thickness of 20 mm, is around 25% lower than that of an equivalent plywood panel.”
It also describes the main areas of use:
“The composite honeycomb structure is mostly used in mechanically stressed zones: cell floors, double floors, storage compartments. […] This structure is also appreciated for table tops.”
And concludes with the key benefits:
“Its lightweight nature reduces the vehicle’s consumption while optimising payload. Its rot-proof behaviour offers excellent long-term durability.”
Nidaplast® solutions for manufacturers and equipment suppliers:
Nidaskin
The nidaskin sandwich panels are made of a polypropylene honeycomb core with an 8 mm cell size. Each side has a pre-bonded skin.
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Nidaplast 8
Nidaplast 8 is the standard product in the range. It is suitable for hand lay-up or spray-up lamination processes.
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Nidaplast 8DB
Nidaplast 8DB has been specifically designed to make the production of shaped parts easier. Its 30 × 30 mm checker-cut pattern on one side of the core allows the creation of curved components.
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