<p>Honeycomb structures made from the chosen core materials, brass and copper, were designed and fabricated to analyse their flexural properties across various sizes. The honeycomb core structure was designed using software with a cell size of 6&#xa0;mm and node size of 3&#xa0;mm half of the honeycomb core was fabricated using a 30T press in a claw model. The design of core structure was used for making a die and to make a core. A custom pressing tool was developed to achieve a perfect core structure, which was joined using brazing. The honeycomb core was traditionally produced using the in-gear rolling process to increase production rate; however, this method has limitations in accuracy, particularly in corner bending, flatness, and cell shape. It also requires higher torque to produce thicker cores and is difficult to control when problems arise during processing. To address these issues, a press-type forming method was introduced, and various failure modes were investigated. Although different joining processes have been used for core materials, bonded structures are the most common. In this case, employed a press-type method to fabricate the core with improved accuracy and cost-effectiveness, followed by a brazed bonding structure to join the core to the panels. The brazing joints did not fail before the core material cracked. Mechanical properties of the honeycomb panels were evaluated through Bending resistance and core shear stress analyses. The Maximum applied force of various panels was compared, and load–displacement curves were plotted for different core heights at room temperature. Brass honeycomb panels exhibited higher Bending resistance and Shear stiffness of the core, outperforming copper cores. Brass panels provided better stability and flexural properties. Applications include gaskets for brass honeycombs and aerospace and marine industries for copper honeycombs due to their conductive, damping, corrosion resistance, and high strength-to-weight ratio characteristics.</p>