Manufacturing system to form a honeycomb core and a method of forming the same

A manufacturing system to form a honeycomb core, the system comprising:

• a perforation assembly configured to receive a sheet of fibrous material and perforate the sheet of fibrous material to form a plurality of holes through the sheet of fibrous material,
• wherein the sheet of fibrous material has a plurality of strips of adhesive thereon, and the holes are spaced apart from the strips of adhesive,
• wherein the perforation assembly is further defined as a die assembly including a male die and a female die,
• wherein the sheet of fibrous material is fed into the die assembly between the male die and the female die to perforate the sheet of fibrous material to form the holes through the sheet of fibrous material, and
• wherein at least one of the male die and the female die includes an outlet configured to allow coating to exit out of the at least one of the male die and the female die during punching of the sheet of fibrous material such that the coating is applied to the sheet of fibrous material at the holes;
• a cutting apparatus configured to cut the sheet of fibrous material to form a plurality of layers;
• a stacking apparatus configured to stack the layers on top of each other such that the holes of the layers align with each other and the strips of adhesive bond the respective layers together to form a perforated stack;
• the coating applied to the sheet of fibrous material at the holes;
• an expansion apparatus configured to expand the perforated stack to form a honeycomb panel;
• and
• a container configured to contain a solution and receive the honeycomb panel, wherein the coating repels the solution, and wherein the solution adheres to the honeycomb panel except at the holes where the coating is applied to form the honeycomb core.