CIMERA® for Lightweight Structures
The structural Problem, Thin walls, high loads, weight targets that don't move
In structural lightweight applications, the design target is usually fixed: a defined load case, a defined deflection limit, and a weight budget that leaves no margin. Monolithic fiber composites, CFRP, GFRP, can hit stiffness targets, but at thicknesses that push mass beyond budget. Adding fiber plies increases stiffness but also adds weight. Reducing ply count saves weight but reduces stiffness. For thin-walled components in the 0.5–3 mm range, this tradeoff has historically been difficult to escape.
How CIMERA® fiber changes the calculation
Sandwich efficiency in a sub-millimeter construction
CIMERA® fiber places carbon, glass, Kevlar, or Zylon fiber skin layers on either side of a MILLIFOAM® core, starting at total thicknesses from 0.12 mm. The core shifts the fiber skins away from the neutral axis, dramatically increasing the second moment of area, and therefore bending stiffness, without adding significant mass.
Compared to a monolithic fiber laminate meeting the same bending stiffness requirement, CIMERA® fiber reduces component weight by up to 60%.
| Parameter | Value |
|---|---|
| Total thickness | from 0.10 mm |
| Fiber skin materials | fiber, glass |
| Fiber area weight | from 30 g/m² |
| Sandwich area weight | from 95 g/m² |
| Weight reduction vs. monolithic CFRP/GFRP | up to 60% |
| Core Material | MILLIFOAM® (multiple grades) |
| Thermal expansion | controllable via skin/core material selection |
Results in application
The following examples show CIMERA® in documented applications. Each comparison uses the incumbent material as the reference baseline.
Envirotainer
Pharmaceutical Air Freight Containers
Envirotainer is the global market leader in active temperature-controlled containers for pharmaceutical air freight. Their containers maintain precise internal temperatures across flight cycles, despite the extreme temperature swings found in aircraft cargo holds.
Panel material requirements: structural load capacity for handling and stacking, low weight to maximize pharmaceutical payload, dimensional stability across large thermal differentials, and internal airflow geometry supporting extended periods of autonomous operation.
CIMERA® sandwich panels with fiber-reinforced skins and a MILLIFOAM® core are used for both structural enclosure and internal airflow management within the container.
![4a manufacturing envirotainer application [ai modified]](https://www.cimera.at/wp-content/uploads/2026/07/lightweight_2-1024x618.webp)
Steel microsandwich replaces aluminum at 30% lower weight cost-neutral
- Weight reduction: −30% vs. 1.2 mm aluminum
- Total thickness: unchanged at 1.2 mm
- Cost: neutral vs. aluminum reference part
- Validation: 300,000 km automotive endurance test passed; load protection test passed
- Production: compatible with standard deep-drawing tooling and series production lines
A structural back panel previously manufactured from 1.2 mm aluminum sheet was replaced with a CIMERA® metal sandwich of identical total thickness. Skin layers: 0.12 mm steel. Core: MILLIFOAM®.
The part met all mechanical requirements at lower weight, with no tooling investment and no change to the manufacturing process.
30% lighter, 70% stiffer than GFRP honeycomb
- Weight reduction: −30% vs. GFRP honeycomb construction
- Bending stiffness increase: +70% vs. reference
- Result: lower weight and higher structural performance simultaneously, without a thickness penalty
A loading floor panel previously built from GFRP with a honeycomb core was replaced with a CIMERA® fiber sandwich.
Three ways to improve on monolithic CFRP
In a carbon clincher road wheel application, CIMERA® fiber was evaluated against a monolithic CFRP reference construction. Depending on the design target, the sandwich construction enables three distinct optimization paths:
- Same stiffness, less weight - reduce fiber ply count while maintaining structural performance
- Same stiffness, less fiber - achieve the performance target with lower carbon fiber content, reducing material cost
- Higher local stiffness, same weight - increase stiffness in load-critical zones without adding mass
The appropriate path depends on the specific design constraints and cost targets of the application.
Working on a weight-critical component?
CIMERA® fiber and CIMERA® metal are available for evaluation in your application. Contact us to discuss material selection, layer configuration, and testing requirements.
