CORE MATERIALS
At Orca Composites, we understand that a strong, reliable core is critical to the performance of your composite structure. That's why we offer a diverse range of core materials—each designed to optimize strength-to-weight ratios, improve durability, and simplify manufacturing for a variety of industries, including marine, transportation, wind energy, civil engineering, and more.
No matter the application, Orca core materials are engineered to deliver outstanding performance, hassle-free application, and long-term value.
Comprehensive Core Solutions -Lightweight Strength, Durability, and Versatility
Our core material lineup includes advanced options to meet a wide range of structural, thermal, and environmental requirements:
- ORCA BOARD – Laminated Composite Panel Core: Developed as a superior alternative to plywood, ORCA BOARD delivers high strength and stiffness at a fraction of the weight. Its GRP laminate provides waterproofing and added rigidity, while the solid core allows for easy joining, bonding, and finishing across marine, transportation, wind energy, and industrial applications.
- ORCA PVC – Closed-Cell Cross-Linked PVC Foam Core: Offering superior strength-to-weight ratios, excellent mechanical properties, and outstanding chemical resistance, ORCA PVC is compatible with polyester, vinyl ester, and epoxy resins. Available in multiple densities and sheet sizes, it's ideal for marine, transportation, wind energy, aerospace, and sporting goods applications.
- ORCA AIR THERMOPLASTIC HONEYCOMB – Lightweight Polypropylene Core: Combining lightweight resilience with excellent sound dampening and corrosion resistance, ORCA Air is available in plain, contoured, and double-contoured finishes with standard non-woven veils and barrier films. Ready-to-use kit options are available for faster processing and reduced material waste.
- ORCA FOAM – Hybrid Polyurethane/Polyester Foam Core: A cost-effective alternative to traditional foam cores, ORCA Foam offers excellent mechanical performance across a range of densities. It's perfect for applications requiring lightweight strength and durability in sandwich structure designs.
Core Materials Designed for Demanding Environments
Whether you’re constructing advanced marine vessels, lightweight transportation structures, renewable energy components, or industrial solutions, Orca Composites has a core material engineered for your performance, processing, and cost goals.
Detailed Product Overview:
ORCA BOARD:
- Applications: Marine, Road and Rail, Wind Energy, Industrial
- Features: Superior plywood replacement, High strength-to-weight ratio, Dimensionally stable, Easy to work with standard tools, Excellent moisture, sound, and thermal resistance, Cost-effective alternative for structural needs
ORCA PVC:
- Applications: Marine (Leisure, Military, Commercial), Transportation, Wind Energy, Civil Engineering, Aerospace, Sporting Goods
- Features: Superior strength and stiffness-to-weight ratios, Outstanding thermal insulation, Excellent chemical resistance and negligible water absorption, Self-extinguishing, Good adhesion with epoxy, polyester, and vinyl ester resins, High process temperature resistance
- Processing Techniques: Vacuum Infusion, Resin Infusion, Contact Molding, RTM (Resin Transfer Molding)
- Available Densities & Sheet Sizes: PVC 40, PVC 60, PVC 80, PVC 100, PVC 130, PVC 200, PVC HT 60, PVC HT 80 - Various standard sheet dimensions to fit different project needs
ORCA AIR THERMOPLASTIC HONEYCOMB:
- Applications: Leisure and Commercial Marine (decks, bulkheads, stringers, transoms), Road and Rail Transportation (floors, sleeper cabins, trailer beds), Industrial (exhibits, shower bases), Infrastructure (portable buildings, cladding, interiors)
- Features: High strength-to-weight ratio, Excellent sound damping properties, Corrosion, rot, and moisture resistance, Wide temperature range (-22°F to 176°F), Recyclable, Available in customized ready-to-use kits for minimal waste and faster production
ORCA FOAM:
- Applications: Ideal for sandwich structures needing economical strength and lightweight performance
- Features: Hybrid polyurethane/polyester formulation, Available in multiple densities to match structural needs, Excellent mechanical properties, Suitable for a wide range of lightweight structural applications
Client-Oriented Production & Rapid Turnaround
At Orca Composites, we prioritize our clients’ success above all else. This commitment drives our approach to material innovation and problem-solving. By manufacturing and testing in-house, we maintain complete control over the development process, allowing us to quickly refine formulations and scale production with both speed and precision.
For our clients, this means faster turnaround times, consistent quality, and tailored solutions that address your specific performance needs. Whether optimizing for strength, weight reduction, durability, or process efficiency, our hands-on approach ensures that every material we produce aligns seamlessly with your manufacturing goals. In fast-moving markets where delays can mean lost opportunities, our ability to rapidly develop and deliver high-performance composite solutions translates to a decisive competitive advantage for our clients.
Bespoke Solutions
We formulate materials tailored to your performance, quality, and cost goals.
Fast Development & Scale-Up
Small-batch testing ensures optimal performance before ramping up to full-scale production.
Reliable & Consistent Quality
Each batch undergoes rigorous testing to guarantee peak performance.
A Commitment to Your Success
Orca Composites does more than supply high-performance composites solutions — we deliver professional peace of mind to our clients. Our products are engineered for durability, consistency, and peak performance in the most demanding environments.
But what truly sets us apart is our proactive approach to supply chain diversification. By building a resilient, multi-source network and maintaining deep inventory buffers, we help ensure our clients stay on schedule — even when the unexpected hits.
Whether you're tackling a large-scale build or an intricate specialty application, Orca Composites is here to support your success with tailored solutions, technical expertise, and dependable delivery.
Partner with Orca Composites — and move forward with the confidence that your core material needs are covered, today and tomorrow.
Contact us today
to discuss your specific core materials requirement(s) and discover the difference our client-driven approach can make for you and your business.
