What are Phenolic Panels & How are they Made?

Introduction to Phenolic Materials

In the ever-changing world of architectural design, staying ahead of material trends and continually evolving design thinking is critical. North America is now the fastest-growing market for phenolic panels in the world.   The material has been used in Europe for over 60 years based on its proven performance characteristics in interior design and exterior rainscreen applications. Increasingly, designers in the United States and Canada are finding new ways to use phenolic panels for facades, lockers, interior wall linings, and scientific work surfaces. But what are phenolic panels (sometimes called solid phenolic or compact laminate), and how is it made?

Phenolic panels are constructed by embedding layers of paper or fibrous materials into phenolic resin then applying high pressure and heat to transform them into a solid composite panel that will not delaminate or degrade over time.

How Are Phenolic Panels Made?

1. Kraft Paper

Specially selected core paper with precise color, weight, and tear strength parameters is sourced from renewable wood products. The foundation of its high strength-to-weight ratio comes from long fibers within kraft paper that allow the paper to be impregnated by the resin in step two. 

2. Phenolic Resin

The core papers are impregnated with phenol. Phenolic resin can be mixed with flame retardant additives, which keeps the panel core flexible, resulting in a high modulus of elasticity.

3. Layers

After impregnating core papers with thermoset resins, they are dried, cut, and placed on steel plates. The desired panel thickness determines the number of core paper layers needed for production in a stack. 

4. Pressure + Heat

Under controlled pressure and heat, the thermosetting resin joins the individual components to form a single homogeneous and monolithic panel. The result is a high-density and extremely durable product that resists UV, scratching, and impact, as well as chemical attack and water intrusion. The material remains flexible and easy to cut with traditional tools.