Abstract: Provided is a composite sandwich panel. The composite sandwich panel includes a core, a first thermoplastic layer applied to a first side of the core, and a second thermoplastic layer applied to a second side of the core. The core is provided in the form of a wave board formed from natural fiber. Also provided is a process for manufacturing a composite sandwich panel. The process comprises extruding a first and second thermoplastic layer into respective flat sheets, forming a consolidated natural fibrous mat, and molding the consolidated natural fibrous mat into a consolidated core having a predetermined geometry. The first and second thermoplastic layers, as well as the consolidated core are heated to a predetermined molding temperature. The heated consolidated core is placed between the heated first and second thermoplastic layers, and the assembly is molded in a molding press into a desired shape determined by product design intent.

Abstract: Provided is a composite sandwich panel. The composite sandwich panel includes a core, a first thermoplastic layer applied to a first side of the core, and a second thermoplastic layer applied to a second side of the core. The core is provided in the form of a wave board formed from natural fiber. Also provided is a process for manufacturing a composite sandwich panel. The process comprises extruding a first and second thermoplastic layer into respective flat sheets, forming a consolidated natural fibrous mat, and molding the consolidated natural fibrous mat into a consolidated core having a predetermined geometry. The first and second thermoplastic layers, as well as the consolidated core are heated to a predetermined molding temperature. The heated consolidated core is placed between the heated first and second thermoplastic layers, and the assembly is molded in a molding press into a desired shape determined by product design intent.