by | Sep 27, 2025
COMPOSITE PANELS / / E En nd d G Gr ra ai in n B Ba al ls sa aDuFLEX
TM
DuFLEX
TM
panels are specifically designed to reduce
construction time and to optimise structural weight in
high performance composite structures. Time-
consuming laminating, coring and vacuum bagging
steps normally required to fabricate high performance
composites are avoided, and material waste, labour
and tooling costs are greatly reduced.
DuFLEX
TM
panels are 2400mm x 1200mm with
multiaxial E-fibreglass or carbon fibre skins, laminated
with a high performance epoxy resin. Fibre orientation
and ply schedules are based on design or engineering
specifications to best meet weight targets, stress and
impact loads, and other design parameters.
The laminates are finished with peel ply to protect the
laminate from contamination and to reduce
preparation of the surface prior to secondary
bonding or laminating.
End grain balsa has an extremely high strength-to-
weight ratio, excellent mechanical properties, good
thermal and sound insulation properties, high impact
and fatigue resistance and good moisture resistance.
Typical applications include hull shells, decks, super-
structures, bulkheads, frames and stringers in one-off
construction, prototypes and running plugs. Non
marine applications include, rail floors, wall, doors,
roof and interior partitions, automotive floors and
truck bodies, and architectural long span roofing and
partitions.
Tensile Strength
Tensile Modulus
Compressive Strength
Compressive Modulus
TYPICAL LAMINATE PROPERTIES
Laminate thickness 0.53mm per 600gm Fibre Fraction 62-664% weight fraction
Test Method
ASTM D3039
ASTM D3039
ASTM C-273
ASTM C-273
Biaxial
– Warp (0
o
)
371.9 MPa
21.27 GPa
293.8 MPa
21.27 GPa
Biaxial
– Fill 90
o
327.6 MPa
18.22 GPa
255.5 MPa
18.22 GPa
DUFLEX Balsa – DP1019C6
13mm Plywood- 5ply
Solid Layup 9x C600+M225
4mm Steel Plate
6mm Aluminium
MATERIAL COMPARISONS
35
30
25
20
15
10
5
0
DUFLEX
DP1019C6
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Weight (kg/m
2
)
6mm
Aluminium
35
30
25
20
15
10
5
0
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Pressure to Failure (kPa)
based on a 1m x1m panel
6mm
Aluminium
10
9
8
7
6
5
4
3
2
1
0
DUFLEX
DP1019C6
DUFLEX
DP1019C6
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Deflection (mm)
2.5kPa pressure on a 1m x1m panel
6mm
Aluminium
Weight (kg/m
2
)
5.1
8.1
16.9
31.4
16.2
Deflection (mm)
3.4
7.4
9.5
8.6
7.1
Pressure to Failure(kPa)
35
5
30
19
18
NOTE Our products are intended for sale to industrial and commercial customers. We
request that customers inspect and test our products before use and satisfy themselves as
to contents and suitability. Nothing herein shall constitute a warranty, express or implied,
including any warranty or merchantability or fitness, nor is protection from law or patent
to be inferred. All patent rights are reserved. The exclusive remedy for all proven claims
is replacement of our materials and in no event shall we be liable for special or
consequential damages.
22/10/09
Nominal Weight kg/m
2
3.8
4.2
4.7
5.1
6.0
6.0
6.5
6.9
7.2
8.3
STANDARD STOCK DuFLEX WITH BALTEK
BALSA CORE 150 kg/m
3
Order Code*
DP1010C6
DP1013C6
DP1016C6
DP1019C6
DP1025C6
DP2010C6
DP2013C6
DP2016C6
DP2019C6
DP2025C6
Description
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
C ore
Thickness
10 mm
13 mm
16 mm
19 mm
25 mm
10 mm
13 mm
16 mm
19 mm
25 mm
*
Example- order code for a 13mm panel with 1 layer of 600 gm biaxial is DP1013C6 – Alternative skin laminates available on request
Sheet size – 1200mm x 2400mm
All timber used in the manufacture of DuFLEX Composite Panels is plantation grown. ATL Composites reserves the right to alter
specifications without prior notice. Weight may vary due to variations in core density.
CUTTING
Diamond-coated fiberglass tooling is recommended
for best tool life. The best edge finish is achieved with
circular saws running aluminium cutting blades,
however blade life is greatly reduced.
KITS
ATL Composites offers in-house CAD and CNC
cutting services, and can produce pre-fabricated
DuFLEX kits from electronic design files.
JOINING
& BONDING
To offset the individual size of the panel, DuFLEX can
be supplied with both long edges pre-machined to
facilitate joining. The Z-Joint is structurally effective
and achieves a smooth and fair surface profile. A
high density epoxy adhesive is specified for joining
DuFLEX Z-joints. Contact ATL Composites for
suitable adhesives.
Manual joining of the panels is also possible,
Contact ATL Composites for specific details.
COMPOSITE PANELS / / E En nd d G Gr ra ai in n B Ba al ls sa aDuFLEX
TM
A AT TL L c co om mp po os si it te es s P Pt ty y L Lt td d
Tel (+61) 7 5563 1222
Fax (+61) 7 5563 1585
info@atlcomposites.com
www.atlcomposites.com
ATL composites
NNo om mi in na al l D De en ns si it ty y ( (A AS ST TM M C C-227 71 1) )
TTe en ns si il le e S St tr re en ng gt th h p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-229 97 7) )
TTe en ns si il le e M Mo od du ul lu us s p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-229 97 7) )
CCo om mp pr re es ss si iv ve e S St tr re en ng gt th h p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-336 65 5) )
CCo om mp pr re es ss si iv ve e M Mo od du ul lu us s p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-336 65 5) )
SSh he ea ar r S St tr re en ng gt th h ( (A AS ST TM M C C-227 73 3) )
SSh he ea ar r M Mo od du ul lu us s ( (A AS ST TM M C C-227 73 3) )
T Th he er rm ma al l C Co on nd du uc ct ti iv vi it ty y @ @ 2 24 4
o o
C C( (7 75 5
o o
F F) ) ( (A AS ST TM M C C-117 77 7) )
LLi in ne ea ar r C Co oe ef ff fi ic ci ie en nt t o of f T Th he er rm ma al l E Ex xp pa an ns si io on n -Tangential
-Radial
-Longitudinal
RIGID END-GRAIN SHEET PROPERTIES
150 kg/m
3
13.0 MPa
3.52 GPa
12.67 MPa
3.92 GPa
2.94 MPa
159 MPa
0.066 W/m.
o
K
18.9 x 10
-6
m/m/
o
C
12.6 x 10
-6
m/m/
o
C
3.06 x 10
-6
m/m/
o
C
9.4 lb/ft
3
1886 psi
510 ksi
1837ksi
568 ksi
427 psi
22.8 ksi
0.453 Btu.in/hr.ft
2
.
o
F
10.5 x 10
-6
in/in/
o
F
7.0 x 10
-6
in/in/
o
F
1.7 x 10
-6
in/in/
o
F
STORAGE
DuFLEX
TM
panels should be stored flat, out of direct sunlight, and kept dry and clean. Panels supplied with fibreglass skins have
peel-ply on the surface, which should be left in place as long as possible, to protect them from surface contamination.
by | Sep 27, 2025
COMPOSITE PANELS / / E En nd d G Gr ra ai in n B Ba al ls sa aDuFLEX
TM
DuFLEX
TM
panels are specifically designed to reduce
construction time and to optimise structural weight in
high performance composite structures. Time-
consuming laminating, coring and vacuum bagging
steps normally required to fabricate high performance
composites are avoided, and material waste, labour
and tooling costs are greatly reduced.
DuFLEX
TM
panels are 2400mm x 1200mm with
multiaxial E-fibreglass or carbon fibre skins, laminated
with a high performance epoxy resin. Fibre orientation
and ply schedules are based on design or engineering
specifications to best meet weight targets, stress and
impact loads, and other design parameters.
The laminates are finished with peel ply to protect the
laminate from contamination and to reduce
preparation of the surface prior to secondary
bonding or laminating.
End grain balsa has an extremely high strength-to-
weight ratio, excellent mechanical properties, good
thermal and sound insulation properties, high impact
and fatigue resistance and good moisture resistance.
Typical applications include hull shells, decks, super-
structures, bulkheads, frames and stringers in one-off
construction, prototypes and running plugs. Non
marine applications include, rail floors, wall, doors,
roof and interior partitions, automotive floors and
truck bodies, and architectural long span roofing and
partitions.
Tensile Strength
Tensile Modulus
Compressive Strength
Compressive Modulus
TYPICAL LAMINATE PROPERTIES
Laminate thickness 0.53mm per 600gm Fibre Fraction 62-664% weight fraction
Test Method
ASTM D3039
ASTM D3039
ASTM C-273
ASTM C-273
Biaxial
– Warp (0
o
)
371.9 MPa
21.27 GPa
293.8 MPa
21.27 GPa
Biaxial
– Fill 90
o
327.6 MPa
18.22 GPa
255.5 MPa
18.22 GPa
DUFLEX Balsa – DP1019C6
13mm Plywood- 5ply
Solid Layup 9x C600+M225
4mm Steel Plate
6mm Aluminium
MATERIAL COMPARISONS
35
30
25
20
15
10
5
0
DUFLEX
DP1019C6
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Weight (kg/m
2
)
6mm
Aluminium
35
30
25
20
15
10
5
0
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Pressure to Failure (kPa)
based on a 1m x1m panel
6mm
Aluminium
10
9
8
7
6
5
4
3
2
1
0
DUFLEX
DP1019C6
DUFLEX
DP1019C6
13mm
Plywood-
5 ply
Solid layup
9xC600
+M225
4mm
Steel Plate
Deflection (mm)
2.5kPa pressure on a 1m x1m panel
6mm
Aluminium
Weight (kg/m
2
)
5.1
8.1
16.9
31.4
16.2
Deflection (mm)
3.4
7.4
9.5
8.6
7.1
Pressure to Failure(kPa)
35
5
30
19
18
NOTE Our products are intended for sale to industrial and commercial customers. We
request that customers inspect and test our products before use and satisfy themselves as
to contents and suitability. Nothing herein shall constitute a warranty, express or implied,
including any warranty or merchantability or fitness, nor is protection from law or patent
to be inferred. All patent rights are reserved. The exclusive remedy for all proven claims
is replacement of our materials and in no event shall we be liable for special or
consequential damages.
22/10/09
Nominal Weight kg/m
2
3.8
4.2
4.7
5.1
6.0
6.0
6.5
6.9
7.2
8.3
STANDARD STOCK DuFLEX WITH BALTEK
BALSA CORE 150 kg/m
3
Order Code*
DP1010C6
DP1013C6
DP1016C6
DP1019C6
DP1025C6
DP2010C6
DP2013C6
DP2016C6
DP2019C6
DP2025C6
Description
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
1 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
2 x 600gm biaxial E-glass on either side
C ore
Thickness
10 mm
13 mm
16 mm
19 mm
25 mm
10 mm
13 mm
16 mm
19 mm
25 mm
*
Example- order code for a 13mm panel with 1 layer of 600 gm biaxial is DP1013C6 – Alternative skin laminates available on request
Sheet size – 1200mm x 2400mm
All timber used in the manufacture of DuFLEX Composite Panels is plantation grown. ATL Composites reserves the right to alter
specifications without prior notice. Weight may vary due to variations in core density.
CUTTING
Diamond-coated fiberglass tooling is recommended
for best tool life. The best edge finish is achieved with
circular saws running aluminium cutting blades,
however blade life is greatly reduced.
KITS
ATL Composites offers in-house CAD and CNC
cutting services, and can produce pre-fabricated
DuFLEX kits from electronic design files.
JOINING
& BONDING
To offset the individual size of the panel, DuFLEX can
be supplied with both long edges pre-machined to
facilitate joining. The Z-Joint is structurally effective
and achieves a smooth and fair surface profile. A
high density epoxy adhesive is specified for joining
DuFLEX Z-joints. Contact ATL Composites for
suitable adhesives.
Manual joining of the panels is also possible,
Contact ATL Composites for specific details.
COMPOSITE PANELS / / E En nd d G Gr ra ai in n B Ba al ls sa aDuFLEX
TM
A AT TL L c co om mp po os si it te es s P Pt ty y L Lt td d
Tel (+61) 7 5563 1222
Fax (+61) 7 5563 1585
info@atlcomposites.com
www.atlcomposites.com
ATL composites
NNo om mi in na al l D De en ns si it ty y ( (A AS ST TM M C C-227 71 1) )
TTe en ns si il le e S St tr re en ng gt th h p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-229 97 7) )
TTe en ns si il le e M Mo od du ul lu us s p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-229 97 7) )
CCo om mp pr re es ss si iv ve e S St tr re en ng gt th h p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-336 65 5) )
CCo om mp pr re es ss si iv ve e M Mo od du ul lu us s p pe er rp pe en nd di ic cu ul la ar r t to o t th he e p pl la an ne e ( (A AS ST TM M C C-336 65 5) )
SSh he ea ar r S St tr re en ng gt th h ( (A AS ST TM M C C-227 73 3) )
SSh he ea ar r M Mo od du ul lu us s ( (A AS ST TM M C C-227 73 3) )
T Th he er rm ma al l C Co on nd du uc ct ti iv vi it ty y @ @ 2 24 4
o o
C C( (7 75 5
o o
F F) ) ( (A AS ST TM M C C-117 77 7) )
LLi in ne ea ar r C Co oe ef ff fi ic ci ie en nt t o of f T Th he er rm ma al l E Ex xp pa an ns si io on n -Tangential
-Radial
-Longitudinal
RIGID END-GRAIN SHEET PROPERTIES
150 kg/m
3
13.0 MPa
3.52 GPa
12.67 MPa
3.92 GPa
2.94 MPa
159 MPa
0.066 W/m.
o
K
18.9 x 10
-6
m/m/
o
C
12.6 x 10
-6
m/m/
o
C
3.06 x 10
-6
m/m/
o
C
9.4 lb/ft
3
1886 psi
510 ksi
1837ksi
568 ksi
427 psi
22.8 ksi
0.453 Btu.in/hr.ft
2
.
o
F
10.5 x 10
-6
in/in/
o
F
7.0 x 10
-6
in/in/
o
F
1.7 x 10
-6
in/in/
o
F
STORAGE
DuFLEX
TM
panels should be stored flat, out of direct sunlight, and kept dry and clean. Panels supplied with fibreglass skins have
peel-ply on the surface, which should be left in place as long as possible, to protect them from surface contamination.
by | Sep 27, 2025
COMPOSITE PANELS / FRrP bonding angles
Composite Bonding Angles have been designed to This combination of resin matrix, fibre content and
provide a quick and effective means for making right orientation assures optimum mechanical properties
angle joints between composite sandwich panels. while the use of an epoxy adhesive enhances the
Bonding angles are faster and easier to install than bond strength.
standard taped joints and ideal for inaccessible areas Composite Bonding Angles are lighter than equivalent
where fibreglass taping would be difficult.
aluminium, steel or timber sections with superior
Bonding Angles consist of multiaxial E-glass in a high resistance to corrosion and fatigue, and no wet-layup
performance epoxy matrix, peel plied on all surfaces, is required as with standard taped sections since they
with the fibre direction tailored for optimum load are simply installed with appropriate surface preparation
carrying capability and stiffness. and an epoxy adhesive.
The angles are manufactured with peel ply to Typical applications include marine – deck, hull,
provide a textured surface to aid in secondary bulk-head and flooring attachments; road
bonding, and the peel ply is removed prior transportation -truck beds, bodies, side walls and
to supply. bus floor supports; industrial applications floors,
The automated construction process ensures a walls, roofs and cabinetry
consistently superior fibre content and high
quality finish.
PERFORMANCE DATA.
Test Specimen Thickness Nominal Area Failure Load (kN)/ Apparent Shear
1 2 Resisting Shear (mm ) Failure Mode Strength (MPa)
1 21 2 48,400 77.6 part shear through polyester 1.60
bond: part tearing
2 14 14 30,400 68.5 kN shear through epoxy bond 2.25
In both circumstances, failure of the joins was through the adhesive rather than the Bonding Angle
Queensland University of Technology (QUT)
Test report CET 4149/3 ~ tensile tests to fibreglass connections fins.
Sample Data: Specimen 1 polyester bonded: Specimen 2 ~ epoxy bonded
Test equipment ~ Grade A Tinius Olsen Universal Testing Machine, loading rate = 5mm/min
Adhesives Storage
ATL Composites specify the following high density FRP Bonding Angles should be stored flat, and kept
epoxy adhesive for use with our FRP Bonding Angles dry and clean. Peel ply must be removed before
* Techniglue CA 2:1 pre-mixed epoxy adhesive bonding.
* WEST SYSTEM epoxy resin/hardener
thickened with 413 Microfibre Blend
* Pro-Set R Cartridge Adhesive
FRP BONDING ANGLES
Order Code* Description Leg Length Nominal Weight
ANT3042 90 Bonding Angle 42 mm 0.30 kg/m
ANT5084 90 Bonding Angle 84 mm 1.00 kg/m
All bonding angles are supplied in 2400mm lengths
toques ho somes ape! od tec peda Ele ear sat tame ot ATL composites Pty Ltd
fer and aby. Noi fn hc ewan xe ped Tel (+61) 7 5563 1222
to be infered, Al poten rights are reserved. The exclusive remedy fr al proven claims Fox (+61) 7 5563 1585
is replacement of our merls ond in no event shall we be lable for speci oF info@otlcomposites.com
consequential damages. 14.05.19 ATL composites www.atlcomposites.com
by | Sep 27, 2025
COMPOSITE PANELS / FRP bonding angles
Composite Bonding Angles have been designed to Composite Bonding Angles are lighter than equivalent
provide a quick and effective means for making right aluminium, steel or timber sections with superior
angle joints between composite sandwich panels. resistance to corrosion and fatigue, and no wet-layup
Bonding angles are faster and easier to install than is required as with standard taped sections since they
standard taped joints and ideal for inaccessible areas are simply installed with appropriate surface preparation
where fibreglass taping would be difficult. and an epoxy adhesive.
Bonding Angles consist of multiaxial E-glass in a high Typical applications include marine- deck, hull, bulk-
performance epoxy matrix, peel plied on all surfaces, head and flooring attachments; road transportation
with the fibre direction tailored for optimum load truck beds, bodies, side walls and bus floor supports;
carrying capability and stiffness. The automated industrial applications – floors, walls, roofs and
construction process ensures a consistently superior cabinetry.
fibre content and high quality finish. This combination
of resin matrix, fibre content and orientation assures
optimum mechanical properties while the use of an
epoxy adhesive enhances the bond strength.
PERFORMANCE DATA
Test | Specimen Thickness Nominal Area Failure Load (kN)/ Apparent Shear
1 2 Resisting Shear (mm?) _ Failure Mode Strength (MPa)
1 2 2 48,400 77.6 part shear through polyester 1.60
bond: part tearing
2 14 14 30,400 68.5 KN shear through epoxy bond 2.25
In both circumstances, failure of the joins was through the adhesive rather than the Bonding Angle
Queensland University of Technology (QUT)
Test report CET 4149/3 tensile tests to fibreglass connections fins.
Sample Data: Specimen 1 polyester bonded: Specimen 2 epoxy bonded
Test equipment Grade A Tinius Olsen Universal Testing Machine, loading rate = S5mm/min
ADHESIVES STORAGE
ATL Composites specify the following high density FRP Bonding Angles should be stored flat, and kept
epoxy adhesive for use with our FRP Bonding Angles dry and clean. Peel ply must be removed before
* Techniglue CA – 2:1 pre-mixed epoxy adhesive bonding.
+ WEST SYSTEM brand epoxy resin/hardener
thickened with 403 Microfibre Blend
* Pro-Set R Cartridge Adhesive
FRP BONDING ANGLES
Order Code* Description Leg Length Nominal Weight
ANT3042 90 Bonding Angle 42 mm 0.30 kg/m
ANT5084 90 Bonding Angle 84 mm 1.00 kg/m
All bonding angles are supplied in 2400mm lengths
NOTE Our products are intended for sale to industrial ond commercial customers. We C4) ATL composites Pty Ltd
reques tho customers inpect and fst our products before use and sail themselves os Tel (461) 7 5863 1222
to contents and suai. Nothing herein shall conse a worant, express or imped,
including ony warraniy or merchantability or fiiness, nor is protection from law or potent Fox (+61) 7 5563 1585
1 feocenent of cur meters and no ens whe heble fo spel or info@atlcomposites.com
consequential damages. 8/07/04 ATL composites www.atlcomposites.com
