Updated on August 20, 2026 • 3 min read
B&T Composites has developed a custom carbon fiber sandwich panel system for a customer requiring large, lightweight composite structures capable of continuous outdoor exposure in a demanding maritime environment.
The Greece-based composites manufacturer engineered panels measuring more than 3.5 meters in length and up to 30 millimeters thick, combining carbon fiber prepreg skins with a PVC foam core.
Rather than adapting an existing standard sandwich panel, B&T Composites says the material architecture was developed specifically around the structural and environmental requirements of the application.
Carbon Fiber Prepreg Skins Combined With PVC Foam
The sandwich construction uses carbon fiber prepreg as the outer skins with PVC foam forming the lightweight core.
In a sandwich structure, the skins and core perform different structural functions. The configuration can provide high bending stiffness at relatively low weight, making sandwich panels useful for applications where both structural performance and mass are important.
For this project, B&T Composites tailored the layup and core configuration to the customer’s requirements.
The finished panels exceed 3.5 meters in length, making manufacturing control an important consideration across the complete component area.
B&T has not disclosed the specific vessel, customer or final location of the panels.
Panels Designed for Continuous Maritime Exposure
Environmental conditions were another central consideration in the panel development.
The components are intended to remain outdoors continuously in a maritime environment, where composite structures can be exposed to moisture, temperature changes and other environmental conditions throughout their service life.
B&T Composites incorporated protective surface finishing as part of the manufacturing process.
The company has not disclosed additional details regarding the coating system, prepreg resin chemistry or specific environmental qualification requirements, so the exact protection strategy has not been specified.
Engineering and Manufacturing Completed In-House
B&T Composites handled the complete project internally, from engineering through production and finishing.
Its work covered panel engineering, prepreg layup, manufacturing and protective surface treatment.
Keeping these stages within the same organization gives the company control over the complete manufacturing route for the customized sandwich construction.
The project also demonstrates an application of prepreg processing outside aerospace, where carbon fiber sandwich structures are increasingly used when large dimensions, low mass and structural performance need to be combined.
B&T Expands Composite Manufacturing Capabilities
The maritime project follows several manufacturing investments and partnerships announced by B&T Composites during 2026.
Earlier this year, the company installed a multi-material automated fiber placement (AFP) system supplied by Mikrosam, expanding its capabilities for both thermoplastic and thermoset composites.
B&T Composites also signed a memorandum of understanding with Dynamit Nobel Defence to explore opportunities to support composite components for defense programs.
The company already works with processes including filament winding, AFP and precision machining.
Its latest sandwich panel project adds another example of how these broader composites engineering and manufacturing capabilities are being applied across marine and other industrial markets.
For the maritime application, the key development is not simply the use of carbon fiber. Instead, B&T Composites has engineered the complete sandwich architecture — carbon fiber prepreg skins, PVC foam core, layup and surface protection — around the requirements of a specific large-format structure.
Bruce Zhou is the Founder of Jota Machinery, where he leads the development of equipment for flexible packaging and advanced composite materials. With experience in composite processing since 2011, his work is centered on practical engineering, product reliability, and building long-term value for manufacturing customers worldwide.
About Bruce Zhou