Hi I have designed and specified a panel system that has to be light with a high impact resistance and would welcome your comments on it's strength to cost and time, i.e if it's to belt and braces when something half the price would be 80% as strong

It's a double curved panel so the impact side is in compression

Externally gel coat mixed with talc filler - increased compression and impact resistance
Carbon kevlar mix fibre twill -45 degree +45 degree
Aluminium hex core 30mm
Carbon fibre twill

and or

Externally gel coat mixed with talc filler - increased compression and impact resistance
Diolen
End grain pro balsa 50mm
CSM

I intend to make a GRP female mold lay it up with vacuum bagging
My questions are

Do you glue the core to the inner/outer layer or piece it together when wet
 
The panels are sealed around the perimeter the core can't move anywhere ??

How do you accurately cut the hex core ?


Thanks