Engineered for Structural Performance, Durability & Build Efficiency
DuFLEX® Balsa Panels are purpose-designed to reduce construction time while maximising structural performance in high-load, long-life composite applications. By eliminating the need for hand laminating, coring and full vacuum bagging, DuFLEX® provides:
- Rapid fabrication and clean, consistent build processes
- Reduced material waste and tooling costs
- Excellent stiffness and compressive strength
- High impact resistance and long-term fatigue durability
Every DuFLEX® Balsa panel can be engineered to meet project-specific requirements including impact loads, slamming forces, stiffness targets, weight budgets and long-term cyclic load resistance.
End-grain balsa delivers a unique balance of mechanical and functional properties:
Superior compressive strength and shear capability
High stiffness-to-weight performance for structural efficiency
Excellent resin absorption and adhesion
Inherently high impact and fatigue resistance
Good thermal and acoustic insulation
Reliable fire performance in composite panel systems
These characteristics make DuFLEX® Balsa an ideal solution for robust, lightweight structures exposed to demanding operating environments.
Applications Across Marine, Aerospace, Transport & Industrial Markets
DuFLEX® Balsa Panels are used extensively in structural and semi-structural components across:
Marine
Hulls, decks, superstructures
Internal structures, soles, bulkheads and reinforcement modules
Transport — Road & Rail
Floors, walls, roof panels, front-end and side skirts
High-strength body panels and lightweight transport modules
Aerospace
Aircraft floors and galley structures
Cargo pallets and interior panels
Industrial / Construction
Tooling boards, tanks and process equipment
Composite moulds, concrete forming systems
Architectural fascia panels and structural modules
From one-off fabrications to high-volume production, DuFLEX® Balsa delivers predictable strength, repeatability and extended service life.
Key Advantages of DuFLEX® Balsa Panels
Exceptional mechanical performance
High stiffness and compressive strength
Proven durability and impact resistance
Strong resin adhesion and bonding reliability
Excellent fire, thermal and acoustic performance
Rapid, efficient installation through engineered panel construction
Available in engineered kits for consistent, time-efficient builds
Laminate Construction Engineered Skins for Demanding Loads
Standard DuFLEX® Balsa Panels are laminated with high-performance epoxy resin reinforced with multiaxial E-glass or carbon fibre skins. Fibre orientation and ply schedule are tailored for:
Strength and stiffness requirements
Impact and fatigue considerations
Weight control
Span and load case optimisation
Defence and commercial qualification requirements
Panels are supplied with peel ply for a clean, contamination-free bonding surface, accelerating secondary bonding and laminating.
DuFLEX® Balsa Panels can be supplied with precision-machined Z-Joints to simplify alignment and joining of large panels. When bonded with high-density epoxy adhesive, Z-Joints provide:
Structural continuity across joined panels
Smooth fairing and consistent surface finish
Faster installation with reduced labour
Modulus continuity ensures stiffness is maintained across the joint — essential for hulls, decks and other high-load structures.
ATL Composites provides full CAD-to-CNC processing and can supply DuFLEX® Balsa Panels:
Flat, curved, cut-to-size or fully CNC-nested
With custom laminate schedules
With engineered fibre orientation
With core grade selection tailored to load cases
As complete assembly kits for rapid construction
Send your drawings — ATL engineers, cuts, labels and delivers panels ready for installation.
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
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.
