Two applications, one material

Door manufacturing.

Axxon supplies honeycomb solutions to door manufacturers across two distinct applications: infill panels and cut-to-size honeycomb core for hollow-core door construction and protective sheets to separate doors during transit.

How it works

Metal, wood, paper?

Both steel and wood hollow-core door applications leverage the same core properties advantages of the honeycomb cell structure : rigidity, cost-effectiveness and an incredible strength to weight ratio.

For hollow metal doors: honeycomb core is expanded inside the door cavity to provide continuous backing support. The panel’s cell structure distributes impact forces, eliminating skin flex and the oil-canning sound.

Similarly for hollow-core wood doors: honeycomb core sits inside of the door cavity. The manufacturer laminates facings, typically hardboard or MDF, directly to the core. This create a composite structure that is up to 60% lighter than solid wood with comparable strength properties.

Why it works

Key Benefits of Honeycomb Door Core

  • Weight reduction

    Honeycomb door core is up to 60% lighter than solid wood or particleboard core equivalents. Lighter doors are easier to handle, install, and operate — and reduce freight costs for door manufacturers shipping finished inventory.

  • Structural rigidity

    The hexagonal cell geometry provides high compression resistance, preventing the door from sagging, warping, or deforming over its service life. The core distributes loads across the full door face rather than concentrating stress.

  • Cost effective

    Honeycomb core is one of the most cost-effective structural substrates available for door manufacturing — suitable for high-volume residential and commercial interior door production where material cost is a key driver.

  • Sustainable

    Made from recycled kraft paper with water-based adhesive. Aligns with green building standards and contributes to sustainable construction certifications. Biodegradable and fully recyclable at end of service life.

Products we supply

2 products. One complete package.
Paper honeycomb core stretched open into a full expanded sheet

Door Core

Unfaced honeycomb core supplied to your dimensions.
  • Composite doors up to 60% lighter than solid wood
  • Multiple cell sizes available
  • Recycled kraft, water-based adhesive
See Specs
Stack of four flat paper honeycomb panels with the hexagonal kraft core visible along the cut edges

Cut-to-Size Panels

Panels perfectly sized to create separation between doors during shipping.
  • Distribute weight evenly to eliminate point loading
  • Protect finished/painted surfaces from abrasion/damage
See Specs

Need an application-specific honeycomb solution?

Quiet your doors. Lighten the load.

Leverage the strength of honeycomb cells in your hollow metal or wood-based door manufacturing applications. We’re here to support your design.

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