AEC produces three types of reinforced sandwich structures: X-COR™, K-COR™, and Ceramic Truss Core (CTC). Each of these utilizes an array of pultruded pins arranged in the core of the sandwich structure so as to act as a load carrying truss system.  The pin material choice, reinforcement density, location, and angle of insertion may all be tailored for specific applications, types of loading, and end uses.  For example, more reinforcement can be added where needed for additional strength or alternatively removed where not needed in order to reduce final product weight and cost.

AEC’s sandwich structures are:

  • Similar or lighter in weight compared to metallic or honeycomb alternatives

  • Thermoformable and may be produced in complex shapes

  • Highly tailorable reinforced structures, designed to meet application-specific compression, stiffness, shear and other structural needs

  • Densified in local areas for attachments, meaning no potting or post-fabrication labor is required to add attachments to these areas

  • Able to be designed with certain types of features built into the panel, rather than requiring that they be machined into the product or attached later

Sandwich Technologies




X-COR is a lightweight, pin-reinforced closed cell foam core sandwich structure in which the pins penetrate into the sandwich structure’s facesheet.  Because the pins penetrate the skins, they are mechanically fastened and need no adhesive bond.  X-COR is highly durable and ballistic resistant.



K-COR is a lightweight, pin-reinforced closed cell foam core sandwich structure in which the pins do not penetrate into the sandwich facesheet. Rather, the pins are splayed and captured between the core material and the sandwich structure skin.   K-COR is also highly durable and ballistic resistant. It is also suitable for components that require highly complex contours.

  Ceramic Truss Core

Ceramic Truss Core (CTC) CTC structures utilize the same ‘truss system’ of pins as X-COR™ and K-COR™, but do not include the foam in the center of the sandwich structure.  Instead, the sandwich structure is only comprised of the skin separated by the truss system alone.  These materials are typically produced using ceramic or other high temperature materials and are suitable for high temperature applications.