In many non-aerospace application areas mechanical requirements and weight targets demand a lightweight sandwich design. However the large production cost of honeycomb core materials often prevents their use in low cost sandwich constructions. In this paper the currently employed concepts for the production of honeycomb cores are reviewed to evaluate their potential for a fully automated production with high productivity. Furthermore, two new cost efficient honeycomb materials and their continuous production processes, developed at the K.U.Leuven, are presented These materials and production methods enable an automated in-line production of paper (TorHex) and thermoplastic film (ThermHex) based honeycombs. The continuous in-line lamination and further processing to sandwich parts with fiber reinforced thermoplastic skins shows large potential for cost sensitive applications.