PlastiCell is using Victrex APTIV film to produce lightweight thermoplastic honeycomb structures. The APTIV thermoplastic honeycomb can be thermoformed into shape in combination with fiber-reinforced Victrex PEEK polymer composite skins to create structural parts without using adhesives. Since the parts consist only of PEEK polymer, any scrap and end-of-life parts can be fully recycled. The process consists of two main steps: forming thin APTIV film sheets, in order to create semi-hexagonal shapes, and sequential stacking of sheets and welding with a laser along lines at contact points to achieve melt-bonding. Core blocks can be machined to shape before molding by various processes. Finished structures are produced by press-molding preformed and preheated composite skins onto the honeycomb. The combination of mold pressure and temperature of the mating surfaces causes the honeycomb core to conform to the mold geometry while ensuring good bonding between the core and skins. The material resists impact damage and will not remain deformed by accidental impacts during machining or assembly. It can operate continuously up to 220°C.