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This study focused on the development of thermal insulation boards by utilizing expanded perlite (EP) and expanded polystyrene (EPS) within a lightweight core, in conjunction with a Formica sheet serving as the exterior layer. The sandwich specimens were fabricated by employing epoxy resin as a binding material, with the volume fractions of EP and EPS being adjusted. A detailed assessment was undertaken to evaluate the physical, mechanical, and thermal conductivity via Lee's disc method. The core's flexural strength, modulus, and energy absorption were found to be superior when the EP volume fraction within it was at its ideal level of 100%. As predicted, there was a positive correlation between the thermal conductivity and the proportion of EP particles. Significantly greater swelling and water absorption were seen in sandwiches composed of 100% EP compared to those composed of 100% EPS. The introduction of EP particles into EPS resulted in a reduction in facial wrinkling during flexural failure, as well as an enhancement in deboning and skin delamination. This research study presents significant findings on the behavior of composite materials, which has the potential to contribute to the advancement of thermal insulation technology. [ABSTRACT FROM AUTHOR]