Hi,
I have done a few small testing parts using both Alu-honeycomb (small cell EC stuff) and similar cell size kevlar HC..
The Kevlar HC is much easier to work with, since the it absorbs a small amount of the normal laminating resin at the ends, ant thus bonds much stronger to the outer CF layers in the sandwich.
The Alu HC material seems to be a tad stiffer, but the outer layers shear or tears away from the core much easier than with the Kevlar HC.
(even when bonded with Permabond special HC adhesive)
Also, the Kevlar HC sandwich, seems to handle a lot more compression distortion, before showning a permanent deformation in the surface layer of the sandwich.
On the small cell Alu HC sandwich, a point pressure of approx. 75 kg/ sq-centimetre caused a 1 mm deep permanent deformation in the surface layer.. This did not happen to the Kevlar test sample. It seemed to deform a bit more than the Alu HC, but returned to a flat surface after the pressure was removed.
For the two small parts I made, there was only a very small difference in weight, with the Kevlar being maybe 10% heavier.
No doubt the kevlar HC is an excellent material, but its use is rather specialized with the prices you pay for it.
(I do not build a lot of ultra-light RC planes or F1 Racing car "tubs" :rolleyes
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