Core Options — Divinycell®
Structural Performance
DuFLEX® Foam Panels are available with the complete Divinycell® structural foam core range:
Divinycell® H
Excellent stiffness-to-weight, good impact strength, low water absorption, reliable processing.
Divinycell® HP
Improved elevated-temperature stability, chemical resistance and mechanical efficiency in demanding environments.
Divinycell® HM
Exceptional stiffness density ratio for high-load structures; ideal where strength at minimal thickness is required.
Divinycell® PET
Recyclable thermoplastic core option; cost-effective, tough, lightweight and process-friendly.
These core materials offer outstanding mechanical performance, fatigue resistance, thermal stability and bonding characteristics — making them ideal for advanced composite structures in commercial marine, defence platforms, specialist vehicles, high-load industrial modules and architectural systems.
Applications Across Marine, Transport, Industrial & Defence
DuFLEX® Foam Panels are used extensively across structural and semi-structural composite builds, delivering lightweight efficiency, reliable performance and accelerated construction.
Typical applications include:
Hulls, decks, superstructures and internal modules
Bulkheads, frames, stringers and composite reinforcements
Road and rail walls, floors, doors, roofs and partitions
Specialist transport panels, truck bodies and high-load modules
Long-span roofing, architectural cladding and façade systems
Industrial energy systems and infrastructure components
Defence vessels, mission modules and lightweight tactical platforms
Modular building systems, including prefab structural assemblies
Wet-area modules, shower pods and service cores
Structural vehicle flooring and wall systems for vans, trucks and service vehicles
From one-off custom builds to high-volume production, DuFLEX® delivers consistent quality, predictable structural performance and significant reductions in labour and build time.
Engineered for Strength, Efficiency & Speed of Construction
DuFLEX® significantly reduces the labour, waste and technical complexity associated with traditional hand-laminated composite structures. By eliminating multiple laminating, coring and full vacuum-bagging steps, DuFLEX® panels enable:
- Faster build times with cleaner fabrication
- Reduced material waste and tooling cost
- Controlled, repeatable laminate quality
- Improved strength, impact tolerance and fatigue performance
Every DuFLEX® panel can be engineered to suit the project — laminate schedule, fibre orientation, resin system, and core density can all be tailored to meet precise structural requirements including:
- Weight reduction targets
- High impact and slamming loads
- Span-driven stiffness demands
- Shock, vibration, fatigue and mechanical resilience
Panels are supplied with peel ply for a contamination-free bonding surface to accelerate secondary bonding and laminating.
DuFLEX® panels can be supplied with precision-machined Z-Joints along the long edges to streamline installation. When bonded with a high-density epoxy adhesive, the Z-Joint provides:
Structural continuity
Smooth, fair surface transitions
Faster assembly with high alignment accuracy
This system behaves similarly to a weld in aluminum – modulus continuity is retained, ensuring stiffness performance across the joint.
ATL Composites provides complete CAD-to-CNC service for streamlined production.
We engineer every panel to the requirements of your project:
Custom laminate schedules
Tailored fibre orientation
Optimised core density selection
Structural design for stiffness, weight, fatigue & impact
Supplied flat, curved, pre-cut or fully CNC-kitted
Send your drawings — we cut, label and prepare your full build kit for rapid, clean assembly.
Cutting, Finishing & Fabrication
DuFLEX® can be processed using standard composite tooling. For best results:
Use diamond-coated tools for edge quality and longevity
Aluminium-grade circular blades deliver clean cuts (with shorter life)
Peel ply enables fast, dust-free secondary bonding
Panels can be ripped, machined, drilled and edge-profiled with ease
DuFLEX® Panels can be supplied with calibrated hardwood veneers to create premium decorative surfaces ideal for:
• Marine cabinetry and luxury yacht interiors
• Architectural joinery
• Furniture and commercial fit-outs
• Interior modules and accommodation spaces
ATL also offers a wide selection of surface finishes to suit design, weight and performance requirements, including:
• Melamax laminates
• Laminex laminates
• Carbon, aramid and flax fibres
