Can sandwich panels be custom-cut to non-standard dimensions?

compoform · 08 Aug 2026

Yes, sandwich panels can be custom-cut to non-standard dimensions. Modern thermoplastic composite panels are manufactured in large master sheets and then cut to precise customer specifications using CNC routing, circular saws, or panel saws. For most European OEM applications, custom dimensions are the norm rather than the exception.

Standard off-the-shelf panel sizes rarely match the exact requirements of truck bodies, trailer floors, or scaffolding boards. Custom cutting eliminates on-site trimming, reduces material waste, and ensures panels arrive ready to assemble. The sections below cover how sizing works, what cutting methods are used, and what to consider when specifying non-standard dimensions.

What sizes can sandwich panels be manufactured in?

Thermoplastic sandwich panels can be manufactured in very large master sheet sizes, with maximum dimensions typically reaching up to 13,500 mm in length and 2,950 mm in width, depending on the production line. Thickness ranges vary by core type and application, commonly spanning from around 10 mm to 150 mm.

The maximum sheet size a manufacturer can produce is determined by the width of their continuous production line and the handling capacity of their cutting equipment. Larger master sheets give you more flexibility when nesting custom dimensions, because more parts can be cut from a single sheet with less offcut waste.

Thickness selection is driven by structural requirements rather than production constraints. A wall cladding panel for a cargo box interior might use a 17 mm or 20 mm configuration, while a self-supporting truck body floor panel may require 30 mm or more. Core density also varies: oriented PP foam is available across a wide range of densities, allowing the stiffness and weight of the panel to be tuned to the load case without changing the outer dimensions.

How are sandwich panels cut to custom dimensions?

Sandwich panels are cut to custom dimensions using CNC routing, panel saws, or circular saws with carbide-tipped blades. CNC routing is the most precise method and is suited to complex shapes, cutouts, and repeating production runs. Panel saws handle straight cuts efficiently at high volume. The right method depends on the geometry required and the production quantity.

CNC routing

CNC routing uses a computer-controlled cutting head to follow a programmed path across the panel surface. This method handles straight cuts, angled cuts, internal cutouts for windows or hatches, and complex perimeter shapes in a single setup. For truck body builders and trailer manufacturers producing consistent runs of the same panel geometry, CNC routing delivers repeatable accuracy across every piece.

Saw cutting

Panel saws and circular saws with carbide-tipped or diamond-tipped blades cut thermoplastic composite panels cleanly without delaminating the skins. This method is faster than CNC routing for simple rectangular cuts and is well suited to high-volume production where the geometry is straightforward. The cut edge is clean and can be edge-sealed immediately after cutting to protect the core from moisture ingress.

What’s the difference between off-the-shelf and custom-cut sandwich panels?

Off-the-shelf sandwich panels are stocked in fixed standard sizes and sold without modification. Custom-cut panels are produced or trimmed to the exact dimensions specified by the customer. The practical difference is that off-the-shelf panels require on-site cutting to fit, while custom-cut panels arrive ready to install, reducing assembly time and the risk of measurement errors.

For low-volume or one-off projects, off-the-shelf panels can be a practical starting point if the standard size is close to what is needed. However, for OEM production runs where the same panel dimension repeats across many units, custom cutting at the manufacturing stage is almost always more efficient. You eliminate a production step, reduce scrap, and maintain dimensional consistency across every vehicle or structure.

There is also a quality argument. Cutting composite panels on a factory CNC machine with the correct tooling produces cleaner edges than cutting on a workshop floor with general-purpose tools. Clean edges matter because exposed core material on a cut edge can absorb moisture or UV degradation over time, particularly on truck floors and scaffolding boards that are regularly washed down or left outdoors.

Which applications most commonly require non-standard panel dimensions?

Truck body building, trailer manufacturing, and scaffolding are the applications that most consistently require non-standard sandwich panel dimensions. In each case, the panel must fit a specific structural envelope that does not correspond to any standard sheet size, and dimensional accuracy directly affects assembly quality and structural performance.

Truck body floors and walls: Body dimensions vary by chassis, wheelbase, and customer specification. A floor panel for a 7.2-metre box body is a different cut from one for a 6.0-metre body, and neither matches a standard sheet.
Trailer sidewalls and roofs: Trailer manufacturers work to tight dimensional tolerances. Panels must align with framing members, door openings, and corner posts, all of which vary by trailer type and build standard.
Scaffolding boards: Scaffold plank dimensions are governed by EN 12811 load class requirements and the bay widths used on a given project. Standard plank lengths of 1.8 m, 2.4 m, and 3.0 m are common, but project-specific lengths are frequently requested.
Cargo box interiors: Refrigerated and dry freight boxes use wall and ceiling panels cut to fit around internal framing, load restraint tracks, and ventilation channels.
Façade cladding: Architectural applications often involve panels cut to module widths dictated by the building grid, which rarely aligns with standard composite sheet widths.

In commercial vehicle manufacturing, the shift toward electric drivetrains has added further pressure on panel dimensions. EV truck and van platforms often have different floor heights and structural geometries compared to diesel equivalents, because battery packs occupy space that previously housed fuel tanks and transmission components. Lighter body structures also extend battery range directly: every kilogram of structural dead weight reduces range per charge, making weight reduction a range argument, not just a payload argument. This is a standard procurement question from EV fleet buyers in 2026, and it is driving demand for precisely dimensioned, lightweight composite panels that fit new platform geometries without modification on the assembly line.

Does custom cutting affect the structural performance of sandwich panels?

Custom cutting does not reduce the structural performance of a sandwich panel provided the cut is made correctly and the edges are properly sealed. The core and skin materials retain their mechanical properties after cutting. The main risk is edge exposure: an unsealed cut edge leaves the core material open to moisture, UV, and mechanical damage, which can degrade performance over time.

Edge sealing after cutting is standard practice for panels used in demanding environments. A sealed edge bonds the skin to the core at the cut face, preventing moisture from wicking into the core structure. For scaffolding boards and truck floors that are regularly pressure-washed or exposed to rain, edge sealing is not optional. Edge bending, where the skin material is folded over the cut edge, provides an even more robust solution for high-wear applications.

One consideration when cutting panels to non-standard dimensions is the effect on skin continuity. The glass-fibre reinforcement in the skins runs continuously across the full panel width. When a panel is cut, the fibres at the cut edge are severed. This is normal and expected, and the remaining panel retains its rated performance across its face area. What changes is the edge condition, which is why sealing matters. The structural properties in the middle of the panel, where loads are applied, are unaffected by the cut.

Where can you source custom-cut sandwich panels in Europe?

Custom-cut thermoplastic sandwich panels are available from specialist composite manufacturers based in Europe, primarily in the Netherlands, Germany, and Scandinavia. European sourcing gives you access to custom dimensions, consistent quality, reliable lead times, and post-sales technical support, none of which are reliably available when sourcing from outside the region.

When evaluating European suppliers, the factors that matter most for OEM production runs are:

Maximum sheet size: A larger production line means more flexibility in how your dimensions are nested and cut, reducing offcut waste.
Core and skin options: Different applications need different configurations. A supplier with a limited range will push you toward a standard product rather than the right one.
Cutting capability: Confirm whether the supplier operates CNC routing in-house or subcontracts cutting. In-house cutting gives you tighter dimensional control and faster turnaround.
Edge treatment: Ask specifically about edge sealing and edge bending options, particularly if your application involves outdoor exposure or regular washing.
Technical support: For OEM integration, you need a supplier who will review your design and flag issues before production, not one who ships panels to spec and leaves you to solve problems on the assembly line.

How Compoform Helps with Custom-Cut Sandwich Panels

We manufacture thermoplastic sandwich panels at our facilities in Beek and Ospel, the Netherlands, on a 72-metre semi-automatic production line capable of producing panels up to 13,500 mm × 2,950 mm × 150 mm. Every panel is cut to your exact specification before it leaves our facility.

Here is what that means in practice for your production:

Custom dimensions as standard: We do not sell off-the-shelf sheets and expect you to trim them. Panels are cut to your drawing, including complex shapes, internal cutouts, and angled profiles.
Core and skin configuration matched to your application: We work with PP honeycomb and PET foam cores across a range of densities, combined with glass-fibre thermoplastic skins. The configuration is specified for your load case, not defaulted to a catalogue product.
Self-supporting floor panels: A 30 mm PP sandwich panel floor is self-supporting with no aluminium subframe required. This removes a production step and reduces cost for truck body builders assembling at volume.
Edge sealing and edge bending included: Cut edges are sealed or bent as part of our standard process, protecting the core from moisture and UV on scaffolding boards and truck floors that face regular washdown.
Long service life, lower TCO: Thermoplastic composite floors last significantly longer than plywood in heavy transport applications. Over a 15-year vehicle life, that eliminates multiple replacement cycles. Once you factor in panel cost, installation labour, and vehicle downtime, the composite floor is cheaper per year of service even at a higher unit price.

Before we cut a single panel, we review your design with you. We check that the panel configuration suits your assembly process, flag any dimensional or structural issues, and confirm that the specification will perform as expected in your application. If you are specifying composite panels for a truck body, trailer floor, or scaffolding board and want to discuss dimensions and configuration, speak to our engineering team directly.