Aluminum Honeycomb

(1 customer review)


NOW IN 7/8″ THICKNESS! Aluminum honeycomb is an awesome material to embed in resin for pen blanks, knife scales or any other project you can imagine. Two sizes to choose from: 1/8″ cell or 1/4″ cell in 7/8″ thickness or 1/4″ cell in 2″ thickness. Each sheet is 5″ x 8″ and prices are per 5″x8″ sheet. See Product Description below and videos showing how to prep and cast it for more details. Also available are Variety Packs with one 4.5″ x 6″ sheet of each style.

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Finally, a reliable source of aluminum honeycomb for resin casting! Honeycomb adds a whole new dimension to your turning blanks, and it’s fun to get creative with for pen making, knife making, or any other resin project.

Each piece is 5″ x 8″.  There are three sizes to choose from: 1/4″ cell and 1/8″ cell in 7/8″ thickness or 1/4″ cell in 2″ thickness. NOTE: I’m in the process of switching the 3/4″ thickness sheets to 7/8″ thick sheets. 1/8″ and 1/4″ cell sheets now come in 7/8″ thickness, and once all the 3/4″ thick pieces in 1/4″ cell is gone, I will be switching to 7/8″ thick pieces in the Variety Packs too. Prices are for one 5″ x 8″ sheet.

I wanted to purchase aluminum honeycomb to use in my blanks, but I could never get any straight answers about which type or what brand adheres best to casting resins. So, I decided to just test a bunch of different brands out and use the one that worked best. After extensive testing with different manufacturer’s products, this aluminum honeycomb gave the best results for adhesion with resins. I’ve turned numerous pens without any major tear-out, and I even had other pen makers of varying skill levels test out blanks made with this honeycomb. It worked fabulous! Since I did the testing to ensure that the blanks I make have the best adhesion possible with the honeycomb material, I can also pass on that benefit to my customers.

This material is brand new, not scrap left over from worksites. To ensure the product quality remains consistent, I buy full sheets brand new directly from the manufacturer.

Note: Although this is the best product I’ve found, the bond between aluminum honeycomb and resin is not ideal and could delaminate depending on conditions and factors during casting and while turning/processing. My testing showed minimal chipout overall using specific resins and turned by numerous different people with different pen turning skill levels, but all the blanks used during the testing period were made by me using my processes and resin products.

Caution must be taken while turning blanks with this material embedded in it.  The bond between the resin and honeycomb is fragile and can delaminate if overheated or stressed. For best results soak the material in acetone for 30 minutes and dry fully prior to casting to help remove any oils or other surface contaminants that may weaken the bond between the resin and honeycomb. To provide additional adhesion after casting and during turning, use super thin CA glue to strengthen any weak spots.

For help on how to prepare and examples of casting aluminum honeycomb, watch the videos below:

Cutting Aluminum Honeycomb Prior to Casting:

Casting Aluminum Honeycomb Live:

Example Video Making Hybrid Pen Blanks:


Preparing and turning mixed material blanks

Tips on best practices when working with delicate blanks.

Dimensions N/A
Cell Size

1/4" Cell – 7/8" Thick, 1/8" Cell – 7/8" Thick, 1/4" Cell – 2" Thick, Variety Pack

1 review for Aluminum Honeycomb

  1. Robert (verified owner)

    Great honeycomb,Geat service and very fast shipping.I will be buying again and again.

    • Zac Higgins

      Thanks so much Robert!! Glad to hear you’re enjoying it =D

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