Honeycomb
Cardboard Sheets
Rigid, flat and startlingly light. Paper honeycomb board sheets give you plywood-class stiffness at a fraction of the weight — cut to your size and thickness, 100% recyclable, and made in Balakong, Selangor.
What makes a honeycomb sheet different from cardboard
Ordinary corrugated cardboard is built to fold. It has a single fluted layer, it bends easily across the flute, and it collapses under a few hundred kilograms of flat load. That is exactly what you want in a shipping carton and exactly what you do not want in a pallet deck, a display panel or a crate wall.
A honeycomb cardboard sheet is built to stay flat. Its core is thousands of hexagonal cells standing on edge, each one a tiny column. Load applied to the face is carried straight down those cell walls, which is why a 20mm sheet that is mostly air can support a machine, a stacked pallet load or a two-metre exhibition wall without bowing.
The result is a material that lives in the gap between corrugated and plywood: far stiffer and stronger than the former, far lighter and fully recyclable compared with the latter.
Choosing thickness and cell size
Two numbers decide how a sheet behaves. Core thickness governs stiffness over a span — a thicker sheet resists bending over a longer unsupported distance. Cell size governs point-load and crush strength — smaller cells put more wall under every square centimetre. Paper grammage and liner grade fine-tune both.
| Typical use | Core thickness | Cell size | Notes |
|---|---|---|---|
| Layer pads & dividers | 10–15mm | 8–12mm | Flat, light, stacks tight; the corrugated upgrade. |
| Displays, signage, models | 10–25mm | 10–15mm | Takes print and paint; clean cut edges. |
| Crate walls & fitments | 20–40mm | 12–20mm | Impact absorption through progressive cell crushing. |
| Pallet decks & structural panels | 30–50mm+ | 15–25mm | Plywood-class static loads; pair with runners or frames. |
Typical ranges only. Every phb sheet is made to specification — tell us the load, span and finish you need and we will set thickness, cell size and paper grade accordingly.
Sizes and finishing
Sheets are supplied cut to your dimensions, including large formats for panels and pallets. Kraft liners take flexo or screen print for branding, and moisture-resistant coatings or PE lamination are available for humid routes. For die-cut fitments, edge protectors and corner blocks, see honeycomb board packaging.
Working on props, models, furniture prototypes or set pieces rather than packaging? Our thick cardboard sheets for crafts and makers page covers cutting, finishing and small-quantity supply for studios and schools.
A typical brief — illustrative
Picture a display builder making exhibition walls from 10mm foam board and 18mm plywood. The foam bows after a day under the lights; the plywood needs two people to carry and a truck to move. The question that lands in our inbox: can one material replace both?
A 25mm honeycomb sheet with a 12mm cell is the usual answer. Stiff enough to stand two metres tall unsupported, light enough for one person to carry a 1.2m panel under each arm, and it takes printed graphics directly on the kraft face. When the show ends, the walls go into the venue's paper recycling instead of a skip.
Honeycomb cardboard sheets — questions we get asked
What are honeycomb cardboard sheets?
Honeycomb cardboard sheets are rigid sandwich panels made entirely of paper: a core of kraft paper formed into hexagonal cells, glued between two flat kraft liners. The hexagonal geometry spreads load across the cell walls, so a sheet that is mostly air behaves like a much heavier solid board. They are also called paper honeycomb board or honeycomb paperboard.
What thicknesses do honeycomb cardboard sheets come in?
Core thickness starts at roughly 10mm and runs to 50mm and beyond, with cell sizes of about 8–25mm. Thinner, small-cell sheets suit layer pads and displays; thicker, large-cell sheets suit pallets, crates and structural panels. Every sheet phb makes is cut to the customer's specification.
How strong is a honeycomb cardboard sheet compared to corrugated cardboard?
Far stiffer in bending and far stronger in flat compression. Corrugated board is designed to fold into boxes; honeycomb board is designed to stay flat and carry load. Engineered honeycomb panels handle compression forces around 12kN, which is why they replace plywood in pallets and crates rather than replacing carton board.
Are honeycomb cardboard sheets waterproof?
No. Like all paper products, standard sheets lose strength when saturated. Moisture-resistant coatings, PE lamination or wax treatment can be specified for humid transit or damp environments. For permanently wet duty, plastic or treated plywood is the better material.
Where can I buy honeycomb cardboard sheets in Malaysia?
phb (Quinocycle Sdn Bhd) manufactures honeycomb cardboard sheets in Balakong, Selangor, and delivers across the Klang Valley, Johor and nationwide, with export via Port Klang and KLIA. Send your sheet size, thickness and quantity by WhatsApp to +6016-891 6381 or email [email protected] for a quote.
Where honeycomb sheets go next
Tell us the sheet. We'll tell you the spec.
Send the dimensions, thickness and quantity you have in mind — or the job you're trying to do — and get a quote plus a sample kit with three densities to test.