Unicel's honeycomb is produced by preparing metal foil by the use of special cleaning and coating systems. Thin, narrow rows of a high strength structural adhesive is then printed onto the foil. The foil is cut to specific sheet lengths then stacked in such a way that the printed lines of adhesive are staggered relative to each other, sheet to sheet.

High pressure and temperature is applied to the stack of printed sheets to adhere the sheets of foil together at the lines of adhesive. This cured stack of sheets becomes known as a block.

Slices are then sawn from the block on high precision saws. The thickness of the slices is determined by the desired nominal panel thickness minus the thickness of the facings.

Slices are then expanded to the honeycomb's final size. This expanded honeycomb is called a sheet.

Sheets of honeycomb are bonded between two faces consisting of aluminum, stainless steel or combinations of aluminum fuse-bonded to decorative high pressure plastic laminates, producing extremely lightweight, strong panels.