Purpose-Built Fixing Zones for Reliable Attachment
High Density Inserts create reinforced regions within a composite panel that are engineered specifically for surface screw retention, tapping and through-bolting. These areas significantly increase the local compressive and tensile strength of the panel, eliminating risks such as:
screw pull-out
local buckling around fasteners
compression failure under clamping loads
crushing of low-density cores
inconsistent fastener performance
By incorporating inserts during panel manufacture, ATL ensures structurally reliable fixing points that perform consistently throughout the life of the structure.
Integrated Fixing Solutions
Traditional composite construction often requires additional steps such as cutting out low-density core, backfilling with putty, bonding in blocks, or laminating extra reinforcement to create a strong fixing area.
High Density Inserts remove this entire process.
Inserts provide built-in attachment zones, allowing fabricators to securely mount:
- Hinges
- Brackets
- Hardware
- Fasteners
- Load-bearing connections
- Mechanical Fixings
This approach results in:
Reduced labour — no on-site de-coring, filling or re-laminating
Consistent engineering performance — factory-controlled density, thickness and placement
Higher structural reliability — designed and integrated during panel production
Cleaner, faster assembly — ready-to-use fixing zones in every supplied panel
High Density Inserts are also used as perimeter edging, producing a more robust, impact-resistant panel edge. This eliminates the need for post-production reinforcement and prevents edge crushing or fastener breakout in service.
With inserts integrated during manufacture rather than added on-site, fabricators benefit from:
Optimised strength-to-weight performance
Reduced labour and fabrication time
Lower risk of installation errors
Improved repeatability across production runs
ATL can also supply CNC-machined 2D parts with inserts configured to any level of complexity. Nesting software is used to maximise sheet utilisation and minimise waste.
All DuFLEX® and Featherlight® panels incorporating High Density Inserts are fully compatible with a range of resin systems for secondary bonding, including:
Epoxy
Vinyl Ester
Polyester
Polyurethane (PU)
This ensures seamless integration with ATL’s broader composite ecosystem.
