The Aluminum Composite Material ACM Collection FABRICATION GUIDE 3A Composites USA 3ACOMPOSITESUSA.COM 800.626.3365 TABLE OF CONTENTS Introduction 4 Introduction to DIBOND......................................................................................................... 5 Why Choose DIBOND.......................................................................................................... 6 Application Guide................................................................................................................... 7 Fabrication Guide................................................................................................................... 8 Section I Mounting 9 General Notes......................................................................................................................... 9 Mounting Methods.................................................................................................................. 9 Surface Preparation................................................................................................................. 9 Other Considerations.............................................................................................................. 9 Hot Mounting.......................................................................................................................... 10 Cold Mounting General Notes................................................................................................ 10 Cold Mounting Procedures..................................................................................................... 11 Section II Repositioning Vinyl 14 General Notes......................................................................................................................... 14 Surface Preparation................................................................................................................ 14 Repositioning Vinyl............................................
...................................................................... 14 Section III Direct Digital Printing 15 General Notes.......................................................................................................................... 15 Surface Preparation................................................................................................................. 15 Suitable Inks............................................................................................................................ 15 Section IV Direct Screen Printing 16 General Notes......................................................................................................................... 16 Surface Preparation................................................................................................................ 16 Suitable Inks............................................................................................................................ 16 Ink Curing................................................................................................................................ 16 17 Section V Painting General Notes.......................................................................................................................... 17 Surface Preparation................................................................................................................. 17 Suitable Paints......................................................................................................................... 17 Adhesion Test.......................................................................................................................... 17 Application............................................................................................................................... 17 Drying....................................................................................................................................... 17 18 Section VI C
utting General Notes.......................................................................................................................... 18 Knife Cutting............................................................................................................................. 18 Shearing................................................................................................................................... 18 Saw Cutting.............................................................................................................................. 18 1. Table Saws....................................................................................................................... 18 2. Panel Saws....................................................................................................................... 19 3. RipV-grooving Saws........................................................................................................ 19 4. Circular Saws................................................................................................................... 19 5. Reciprocating Saws.......................................................................................................... 19 6. Band Saws........................................................................................................................ 19 OCTOBER 2020 2 of 44 3ACOMPOSITESUSA.COM 800.626.3365 TABLE OF CONTENTS contd. Section VI Cutting contd. 20 Routing..................................................................................................................................... 20 1. Routing For Bending......................................................................................................... 20 2. Making Corners................................................................................................................. 22 o 3. 90 Corners...........................................................................................
............................ 24 o 4. 135 Profile........................................................................................................................ 25 Die Cutting Punching............................................................................................................. 26 1. Steel Rule Die.................................................................................................................... 26 Section VII Forming Curves 27 Cold Forming............................................................................................................................ 27 1. Pyramid Roller.................................................................................................................... 27 2. Press Brake........................................................................................................................ 27 3. Bending Over Clamped Pipe............................................................................................. 28 Appendix I MSDS 29 Material Safety Data Sheet...................................................................................................... 29 Appendix II Specifications 32 Adhesive................................................................................................................................... 32 Fastening.................................................................................................................................. 34 Concepts................................................................................................................................. 35 Drilling...................................................................................................................................... 38 Thermal Expansion................................................................................................................... 38 Storage Guidelines...............................................................................
.................................... 38 Engineering Specifications....................................................................................................... 39 Post-Paint Finishes Chart......................................................................................................... 40 Screen Printing Inks Chart........................................................................................................ 41 UL Certificate of Compliance................................................................................................... 42 Physical Product Specifications Chart...................................................................................... 43 Conclusion.......................................................................................................................... 44 OCTOBER 2020 3 of 44 3ACOMPOSITESUSA.COM 800.626.3365 INTRODUCTION Thank you for choosing a 3A Composites product for your graphic display applications. This Fabrication Guide was created to incorporate the most common fabrication methods that are used with 3A Composites line of graphics display products. Not all fabrication methods are compatible with each product but this format was kept for consistency purposes. The term the substrate is used throughout this guide and is meant to apply to all members of the substrate family unless noted otherwise. Those fabrication methods that do not apply to a certain product are stated with a short explanation and a recommendation for an alternative product that fits that application method. This manual also contains Appendix I which provides a Material Safety Data Sheet section. Appendix II includes an adhesives fastening and storage guidelines section. Any unique product information will be contained in Appendix II. See Table of Contents. An Appendix III section lists products that can be used in conjunction with 3A Compositesproducts. 3A Composites is not responsible for the performance of any of these
products when used independently or with any 3A Composites product. The date of the last revision is shown on the bottom right hand corner of each page. Please make sure you have the most current version by going to 3acompositesUSA.com and selecting the fabrication manual from the downloads section. If you have any further questions about our product or about how to use this manual please feel free to contact us at 1-800-626-3365. PLEASE NOTE TRIALING IS RECOMMENDED TO ENSURE SUITABILITY FOR THE PROPOSED APPLICATION AND FABRICATION BEFORE FULL-SCALE COMMERCIALIZATION. OCTOBER 2020 4 of 44 3ACOMPOSITESUSA.COM 800.626.3365 INTRODUCTION TO DIBOND DIBOND material is an affordable aluminum composite material ACM made of two lightweight sheets of .012 aluminum with a solid thermoplastic core. The material is intended for such applications as point of purchase displays exhibits and kiosks framing archival framing interior signage and exterior signage as well as structural signage. Additionally DIBONDs unique properties lend itself to very unique OEM industrial applications such as engine covers housings etc. The sheets are pre-painted with a polyester paint finish applied to both sides of the sheet. DIBOND material is available in 2mm 3mm and 4mm thicknesses in 4 x 8 4 x 10 and 5 x 10 sheets. The substrate is available in White Matte Jet Black Black Matte Dark Bronze Aluminum Metallic Red High Gloss Matte Yellow High Gloss Matte British Green High Gloss Matte Ultra Marine Blue High Gloss Matte BUTLERFINISH BUTLERFINISH Copper and BUTLERFINISH Steel. Consult the DIBOND website for the most current products at 3acompositesUSA.com. DIBOND material is a UL Underwriters Laboratories Inc. recognized component for electrical signage UL 879. All thicknesses of DIBOND material meet the criteria for ASTM E-84 and are Class 1 or Class A materials. DIBOND material can substitute for .032 .040 .050 .063 .080 .090 .125 aluminum sheet MDO BoardLaminated BoardsCorrugated ACM Boar
ds Thick Gauge Plastics WoodPlywood Products Expanded PVC The DIBOND Collection consists of DIBOND DIBOND Colors DIBOND BUTLERFINISH Metals DIBOND Mirrors DIBOND DIBOND Colors DIBOND BUTLERFINISH Brushed Metals DIBOND Mirrors Alternative aluminum composite materials available E-PANELTM EPL-5TM OCTOBER 2020 5 of 44 3ACOMPOSITESUSA.COM 800.626.3365 WHY CHOOSE DIBOND The Aluminum Composite Material ACM Family DIBOND has been the industrys leading ACM for more than 20 years. It is comprised of two pre-painted sheets of .012 aluminum with a solid polyethylene core. Flattest panel on the market Superior surface protects expensive digital and screen-printed graphics Provides excellent durability in outdoor applications Wont bow or oil can Approximately one half the weight of a solid aluminum sheet Can be routed and returned to add dimension or roll-formed to deliver sweeping curves Available in a wide range of colors and finishes E-PANELTM is comprised of two pre-painted sheets of .008 aluminum with a solid polyethylene core and manufactured in China. Recommended for flat panel applications only EPL-5TM is comprised of two pre-painted sheets of .005 aluminum with a solid polyethylene core and manufactured in China. Recommended for flat panel applications only Applications Wall-mounted Signs Billboards Post Panel Signage Scoreboards ColumnPole Covers Photomounting FasciaSign Bands Routed Sign Faces Point of Purchase Displays CartKiosk Mfg. Transportation Applications Screen Printing Backing for Channel Letters Interior Signage Digital Electrostatic Printing Awnings Custom Exhibit Booths Murals Custom Architectural Signage Workzone Traffic Highway Signage Illuminated Non-illuminated Signage OCTOBER 2020 6 of 44 3ACOMPOSITESUSA.COM 800.626.3365 O O O FOME-COR with ENCORE Technology O O O FOME-COR SINGLESTEP Heat-Activated O O O FOME-COR CANVAS O O FOME-COR JETMOUNT O O O FOME-COR QUICKSTIK Self-Adhesive O O O DISPA O O O
SINTRA CONSTRUCT Ass em bly FOME-COR Me cha nica l O Pos ter Gla zing 0 Pac kag ing Inte rior Sig nag e O Inte rior Des ign Fra min g O Stru ctu ral Sig nag e Exh ibits FOME-COR FOUNDATION Acid-Free Ext erio r Si gna ge PO PD ispl ays Fixt ure s APPLICATION GUIDE O SINTRA VERS SINTRA SINTRA ECLIPSE GATORBLANKS GATORPLAST GATORFOAM 1 GATORFOAM PRO 1 GATORFOAM EXTERIOR GATORFOAM SELF-ADHESIVE LUMEX G E-PANEL EPL-5 DIBOND 1 2 Trialing is recommended to ensure suitability for the proposed application before full-scale commercialization. O 0 1 2 Short term application Medium term application Long term application Archival mounting applications Black GATORFOAM is not recommended for outdoor usage Applications such as workzone signage canopies pylons and column covers OCTOBER 2020 7 of 44 3ACOMPOSITESUSA.COM 800.626.3365 0 FOME-COR FOME-COR with ENCORE Technology FOME-COR SINGLESTEP Heat-Activated FOME-COR CANVAS 3 3 3 FOME-COR JETMOUNT FOME-COR QUICKSTIK Self-Adhesive DISPA SINTRA CONSTRUCT 1 SINTRA VERS 1 SINTRA 1 SINTRA ECLIPSE 1 GATORBLANKS GATORPLAST GATORFOAM Rou ting Saw Cu ttin g 4 For min gC urv es Cre asin g Pun chin g Kni fe C utti ng Em bos sing FOME-COR FOUNDATION Acid-Free Die Cu ttin g Rep osit ion ing Vin yl Dig ital Prin ting Scr een Prin ting Pai ntin g Mo unt ing FABRICATION GUIDE 5 4 5 4 5 4 5 3 2 3 GATORFOAM PRO 2 3 GATORFOAM EXTERIOR 2 3 GATORFOAM SELF-ADHESIVE LUMEX G E-PANEL EPL-5 1 6 DIBOND 1 6 5 Trialing is recommended to ensure suitability for the proposed fabrication before full-scale commercialization. 0 1 2 3 4 5 6 Archival conservation mounting Cold mounting techniques only Face priming will provide better results Do not expose polystyrene foam to solvent-based paints 1-3mm may be cut with a knife or blade May be die cut in gauges up to 5mm or 316
Punch press die set is required OCTOBER 2020 8 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION I MOUNTING General Notes Mounting laminating and bonding are terms that are often times interchanged. For this document mounting is defined as the attachment of the graphic to the substrate. Lamination is the application of a covering film or liquid over the mounted item to either protect the graphic or provide a certain appearance i.e. matte or glossy finish. Bonding also conveys affixing one thing to another. This can involve a graphic to a substrate or one substrate to another. This document uses the term mounting to convey affixing as opposed to bonding. A paper foil plastic or fabric graphic can be mounted to the substrate. With regard to adhesive mounting consideration should follow the adhesive manufacturers instructions. In general determine the minimum amount of adhesive lay down to attain the desired adhesion level. It is advisable to leave the boards for a period of time to setup. Consult the adhesive manufacturers instructions to see what specific times are recommended. Please refer to Appendix I for additional adhesive information. Mounting Methods There are a variety of methods adhesive pressure etc. for mounting a graphic to a substrate. For this document mounting will be broken into two groupings hot or cold mounting with discussion on the various methods of applying pressure. i. Hot mounting provides a heat source to activate the adhesive. Typically this is accomplished with a heat source associated with either a vacuum press or a roller press. ii. Cold mounting typically utilizes a spray or pressure-sensitive film or coating in combination with a roller press. Printed papers foils and fabrics can all be mounted to the substrate provided that the proper types of adhesives are selected. Mounting can be accomplished on most standard equipment capable of applying adhesive and laminating sheets or roll stock to rigid boards. Surface Preparation Surface should
be cleaned and free of any surface contaminates i.e. oils dust particles etc. prior to commencing. The substrate should be cleaned with isopropyl alcohol using a non-colored cloth for best results. It is important not to use thinners or soaps as they may leave a film residue which can affect adhesion. Additionally cleaners containing silicone can interfere with adhesion and are not recommended. Other Considerations Care should be taken when using laminate films on only one side of the mounted graphic. Moisture pickup will be sealed on one side while the other side in not protected from moisture pickup. Bowing may occur because of moisture imbalance. Additionally care should be taken when mounting only one side with spray adhesives. As the mount cures out tensile forces within the adhesive may cause the substrate to bow. It may be necessary to apply a counter-mount of comparable strength on the backside. Finally one must use the minimum amount of tension when mounting with film or pressure sensitive adhesives as too much tension will cause the substrate to bow too little will cause the graphic to wrinkle. OCTOBER 2020 9 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION I MOUNTING Hot Mounting The substrate is not recommended for this fabrication method. Cold Mounting - General Notes Getting Good Adhesion a. To cold mount pressure-sensitive adhesives you need sufficient pressure. You also must make sure that proper spacers are used. Because effective mounting depends on equal force exerted across the entire width of the substrate being mounted the top roll must move down evenly left and right. Even contact between the top and the bottom mounting rolls is essential. b. Adequate pressure helps squeeze out air from between the adhesive the substrate and the print. c. The mount obtained after 3 hours will generally allow for processing. Maximum mount is usually obtained within 24 hours after mounting. d. To test adhesion flex the finished mount. It should not come loose i
n the center. e. Moisture can become trapped between layers of porous material such as paper and cause blisters. The level of moisture in the atmosphere should be reduced before press work. Prints may even have to be predried. f. When tacking prints to the substrate some shops will hang a number of tacked pieces in an upside-down position until they are ready to pass them through. As a precaution it is advisable not to hold them any longer than 10 minutes or the prints may absorb moisture change in dimension and cause bubbles and wrinkles. g. Please contact the film manufacturer for recommendations concerning the use of their respective laminating material in conjunction with the substrate as film choice is the most important consideration. h. It is advisable to use a film with a high green tack strength. When using pressure sensitive films the substrate should be at room temperature to achieve optimal results. Demounting Bad Mounts a. Pressure-sensitive adhesives may be demounted if done within 5 minutes after mounting. The print will probably be ruined but the substrate may be reused. b. Beyond 5 minutes the adhesive has set and other methods will have to be used such as a hot air gun or a hair dryer to peel off the laminate. The remaining adhesive may be taken off with isopropyl alcohol or mineral spirits. Avoiding Wrinkles Surface Blemishes a. Wrinkles can be caused by misalignment of adhesive roll too much pressure or unparallel rolls. b. Small bumps particularly visible with Cibachrome or glossy prints are caused by trapped dirt or hardened adhesive. Good housekeeping and an ionizing static eliminator on the press are important to minimize dirt pick-up. During mounting the back of the print should be checked and wiped down before it is processed. If bumps are caused by hardened adhesive cut open to check use a fresh roll or sheet of transfer adhesive. To prevent strikethrough one might also consider using a print made with thicker paper .007. OCTOBER 2020 10
of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION I MOUNTING Cold Mounting General Notes contd. Clear Overlays a. Clear high-gloss overlays enhance color and protect against fading indoors and outdoors. To avoid blistering do not use overlays clear coatings or sprays which contain solvents. Cold Mounting Procedures By Hand Using Transfer Adhesive a. Take a sheet of transfer adhesive both sides covered by release paper and fold back release paper on one side approximately 12 from one edge. b. Tack on edge of print to exposed adhesive. c. Lift the print slightly remove the rest of the release paper and use a roller or squeegee to smooth the print onto the adhesive. The back of the print is now coated with an adhesive which is protected by release paper. d. Before mounting to the substrate remove excess air between print and adhesive. This is done by turning the print over so that the release paper is up and smoothing out from the center with a squeegee. e. Now peel off approximately 121 of release paper from upper edge and fold back. f. Tack on to the substrate lining up edges. g. Using a hand roller or squeegee closely follow the removal of the liner to eliminate bubbles caused by air entrapment. Work with a small surface at a time approximately 12. Continue this step until the mounting is complete. By Hand or Press Using Spray Adhesive a. Spray adhesive on the back of the piece to be mounted. Spray 6 8 away from the surface. A double coat is best with the second coat applied in a cross direction to the first coat. For mounting most art materials adhesive need only be applied to one surface preferably the print. Avoid using excessive bonding adhesive. b. Before mounting allow adhesive to dry to the touch the adhesive must be aggressively tacky. If there are blisters due to trapped solvent allow slightly longer than 4 minutes of drying time. c. Carefully position piece on the substrate and smooth out if possible to eliminate any wrinkles and trapped solvent. d. If usin
g a press simply turn on the press to complete the mount. e. If mounting is done by hand place a clean sheet of the substrate over the laminated piece and weigh down for 15 minutes to obtain the maximum bond. Depending upon the type of adhesive allow 24 hours for maximum cure out before exposing the laminate to sudden temperature or humidity changes. By Roller Laminator With Adhesive-backed Graphic a. Adjust rollers to the thickness of the substrate to provide adequate pressure for mounting. b. Peel off a 121 section of release paper from the upper edge of the preprinted adhesive backed paper. c. Tack on to the substrate lining up edges. d. Feed tacked edge into nip of rollers keeping printed piece bent away from the substrate. e. As it passes through the rollers strip away the release paper. Make sure there are no wrinkles or trapped dirt. OCTOBER 2020 11 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION I MOUNTING Cold Mounting Procedures contd. Cold Mounting Non-Porous Graphics a. For non-porous material such as PVC other plastics or metal the following types of contact adhesive with solvent may be used. i. Neoprene nitrile polyurethane or other synthetic rubber types ii. Adhesive must be applied to both faces. Parallel beads of adhesive are often preferred because it allows evaporation of solvent providing faster cure. iii. For mounting the substrate to flexible PVC sheets only plasticizer-resistant types of adhesives should be used. Cold Mounting Porous Graphics a. For porous materials such as paper textiles fabrics or wood the following adhesives may be used. i. Contact adhesive with solvent Same systems as for non-porous materials. ii. Construction mastic structural silicone adhesives. b. Considerations such as expected temperature ranges expansioncontraction porous material and size of substrate should be taken into careful consideration when deciding on a method of attachment. Cold Mounting with Pressure Sensitive Tapes a. Pressure sensitive tapes can be use
d for i. Less demanding applications that are stress-free. ii. Adhering parts during installation work. iii. Holding parts while the primary adhesive is curing. b. Trial Pressure sensitive tapes prior to use. OCTOBER 2020 12 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION I MOUNTING TROUBLESHOOTING WHEN USING COLD MOUNTING PRESSES Poor adhesion or bubbles a. Insufficient pressure a. Increase mounting roll pressure if running without spacer shims. If using spacer shims use next smaller size b. Stripping back more than 1 of release paper while tacking on print traps air b. Never strip back more than 1 of release paper c. Premature contact between print and adhesive traps air c. As it is fed through rolls the print should be tilted or bent away from adhesive until it enters the nip d. The print contains moisture d. Pre-dry print andor keep humidity at a low level Curl bowing a. Too much web tension a. Reduce unwind brake pressure Wrinkles a. Misalignment of adhesive roll causing web tension a. Shift the material roll on the bar to release tension b. Top and bottom mounting rolls are not parallel b. Stripping back more than 1 of release paper while tacking on print traps air c. Too much pressure d. Substrate material thickness relative to shim thickness is too great should be no more than 132. c. Reduce roll pressure d. If correctly sized spacer shims are not available zero the nip OCTOBER 2020 13 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION II REPOSITIONING VINYL General Notes Major market brands of vinyl films work well with the substrate. These vinyl films are for the most part flexible PVC films and are produced in various thicknesses color shades and gloss levels. They can also be un-pigmented to act as a UV inhibitor. These films have a layer of adhesive and a siliconized sheet of cover paper. These films generally have excellent adhesion to the substrate. Final selection of a particular vinyl should be made after consultation with the manufacturer to ensure
conformity for its application. For thinner gauge substrates 1mm 2mm the technique of counter-balancing should be considered. A vinyl sheet may be required on the back side of a vinyl covered substrate to prevent the possibility of bowing. As a rule take caution to avoid too much tension when applying vinyl as excessive tension may lead to bowing of the substrate. Surface Preparation a. Surface should be cleaned and free of any surface contaminates i.e. oils dust particles etc. prior to commencing b. The substrate should be cleaned with 70 isopropyl alcohol using a non-colored cloth for best results. It is important not to use thinners or soaps as they may leave a film residue which can affect adhesion. Additionally cleaners containing silicone can interfere with adhesion and are not recommended. Repositioning the Vinyl a. Identify any misaligned or improperly adhered vinyl graphic b. Using a sharp edge or razor blade held at a 45-degree angle to the substrate begin to lift the vinyl taking care to not scratch the substrate surface. c. After lifting enough of the vinyl surface in order to grab between the fingers continue to peel back the graphic byhand proceed with a proper speed so as to not tear or damage the vinyl graphic. d. Once completely removed lay the vinyl graphic face-down smoothly on transfer paper. e. Reposition the vinyl graphic face-up in the proper location on the substrate and gently rub the transfer paper to re-adhere the vinyl graphic. f. Remove the transfer paper and gently press out any wrinkles or bubbles within the vinyl graphic by hand. OCTOBER 2020 14 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION III DIRECT DIGITAL PRINTING General Notes Large format digital printing on flatbed printers has excellent application for the substrate. Although the substrate is available in a wide range of colors that all demonstrate excellent ink adhesion the predominant substrate color is white when direct digital printing. However colored variations of the
substrate may provide vibrant color contrasts depending upon the availability of a white print head on the printer. Surface Preparation a. Surface should be cleaned and free of any surface contaminates i.e. oils dust particles etc. prior to commencing b. The substrate should be cleaned with 70 isopropyl alcohol using a non-colored cloth for best results. It is important not to use thinners or soaps as they may leave a film residue which can affect adhesion. Additionally cleaners containing silicone can interfere with adhesion and are not recommended. Suitable Inks a. Actual ink type depends upon the printer make and model. Consult the printer owners manual for recommendations. Trialing for ink compatibility is always recommended. b. The substrate readily accepts all types of inks including i. Aqueous ii. Solvent-based iii. UV-curable OCTOBER 2020 15 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION IV DIRECT SCREEN PRINTING General Notes Large format screen printing has excellent application for the substrate. The substrate is available in a wide range of colors that all demonstrate excellent ink adhesion. Surface Preparation a. Surface should be cleaned and free of any surface contaminates i.e. oils dust particles etc. prior to commencing. b. The substrate should be cleaned with 70 isopropyl alcohol using a non-colored cloth for best results. It is important not to use thinners or soaps as they may leave a film residue which can affect adhesion. Additionally cleaners containing silicone can interfere with adhesion and are not recommended. Suitable Inks a. When screen printing with the substrate the following inks may be suitable i. Solvent-based ii. VinylAcrylic iii. UV-cured b. Screen Printing inks should be tested in a manner which duplicates your printing process before initiating production. It is advised that you contact the equipment and ink supplier to provide you with specific recommendations to achieve maximum results. It is strongly recommended to consult
the appropriate ink manufacturer regarding any required ink additives such as catalyst for proper adhesion and exterior use. Ink Curing a. The ink once applied must be given proper time and treatment to completely adhere and cure. b. The substrate can must be cured by air drying jet drying under 40 seconds at a maximum temperature of 175F or UV cured. Temperature dwell times in excess of these limits may cause warping or distortion of the panel. OCTOBER 2020 16 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION V PAINTING General Notes Painting is a suitable fabrication option for the substrate whether for artistic expression or more commercial applications. On some projects that involve the substrate a small quantity of custom color may be required that is often not practical to obtain from the factory and post painting is a viable option. Surface Preparation a. Surface should be cleaned and free of any surface contaminates i.e. oils dust particles etc. prior to commencing. b. The substrate should be cleaned with 70 isopropyl alcohol using a non-colored cloth for best results. It is important not to use thinners or soaps as they may leave a film residue which can affect adhesion. Additionally cleaners containing silicone can interfere with adhesion and are not recommended. Suitable Paints a. The substrate readily accepts the following paints if the surface is scuff-sanded Poster colors Acrylic paints Tempera India ink Latex-based pigments Lacquers Acrylic Lacquers Two-part polyurethanes Vinyls Some water-based paints may also be suitable depending upon the application. Adhesion Test a. The paint system chosen should always be tested for adequate adhesion. To test for adhesion conduct the Cross Hatch Test after the paint has dried for at least 24 hours 1. Make 11 parallel cuts 116 apart with a razor blade knife. Make 11 similar cuts at 90 degrees to cross the first set. 2. Across the scored area apply a strip of strong tape such as 610 Scotch tape. Press fi
rmly. 3. Immediately remove the tape by pulling it back upon itself at 180 degrees in one rapid motion. 4. There shall be no removal of the paint squares to obtain a good adhesion rating. Application a. Paints can usually be applied with a brush or roller although conventional air spray equipment will provide a more consistent appearance. b. Consult paint manufacturers literature for recommended application technique and thinning requirements. Drying a. For drying and cure times consult paint manufacturers literature. b. Due to the wide variety of paint products on the market testing is recommended for initial use of any coating system before commercialization. OCTOBER 2020 17 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING General Notes There are many different methods in which cutting can be accomplished. This guide focuses on five primary cutting methods Knife Cutting Shearing Saw Cutting Routing Die Cutting Punching None of the aforementioned methods require cutting lubricants oils or coolants. When necessary laying out a pattern on the surface of the substrate is best achieved with a soft pencil. Knife Cutting The substrate is not recommended for this fabrication method. Shearing The substrate can be easily sheared. However a slight roll-down of the aluminum cover sheet may occur on the impact side. This roll-down area is often referred to as the edge zone. In this area the polyethylene core is compressed and can lead to increased stress between the core and the aluminum cover sheet. Due to this additional stress shearing should be avoided when the edge of the panel is exposed to the environment. When shearing the substrate light markings on the material may be caused by the hold down pads. In order to avoid these markings the hold down on the shear should be fitted with a shock-absorbing rubber pad to prevent damage to the substrate. Figure 1 - Shearing 0.4mm Approx. Rollover of cover sheet when sheared Saw Cutting The substrate is manufactur
ed with a Polyester paint finish. Care should be taken to protect the finish during any sawing operation. In some cases it is best to move the saw blade rather than the substrate when sizing the panels. 1. Table Saws a. Blades should be Carbide tipped or High Speed Steel designed for cutting non-ferrous materials ground thinner from the rim towards the center to prevent pinching. b. The blades should have angled or circular teeth alternate beveled triple ground with the tooth gap wall rounded. c. The chip angle should be 5 to 15 degrees with a clearance angle of 10 to 30 degrees and a tooth spacing of 316 to 1. d. Cutting speeds of 5500 RPM and feeds of 16second are possible. NOTE Table saws are not recommended for cutting sheets larger than 4x4 in size. OCTOBER 2020 18 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING Saw Cutting contd. 2. Panel Saws a. Panel saws provide an effective method of cutting the substrate. These saws whether standard equipment or custom made perform well and have the added advantage of space savings. b. Blades should be the same type used for table saws. 3. Rip V-Grooving Saws a. These saws are typically used for high volume production operations. b. Blades should be the same type used for table saws. 4. Circular Saws a. Circular saws are also used effectively to cut the substrate. These saws should be productionindustrial type equipment. b. Blades should be the same type used for table saws. 5. Reciprocating Saws a. Reciprocating saws work well for cutouts. Care should be taken with portable and reciprocating saws to prevent damage to the substrate surface. b. More than one sheet can be cut at a time by stacking panels. c. If center cutting i.e. Letter cutouts is required a foam pad may be placed under the substrate with the reciprocating blade cutting into the foam. d. The sheets may be clamped or secured with double-faced tape for the cutting operation. When clamping between jaws protect the panel surface against damage. e.
Blades should be high speed steel .03 to .047 thick 316 to 916 wide with hook or circular teeth with alternate angles set or waved at a spacing of .010 to .250. f. Cutting feeds up to 4second are possible. 6. Band Saws a. Band saws may be used to cut irregular shapes or curves. b. Blades should be tempered spring strip steel .03 to .047 thick 916 to 1 wide with skip teeth designed for non ferrous and ferrous materials spaced at a minimum of 10 teeth per inch. c. Cutting speeds of 10000 FPM at a cutting feed of 10second are possible. OCTOBER 2020 19 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING Routing The substrate can be cut to size using either portable commercial or automated routing equipment. Bits should be carbide tipped and kept sharp. Single or multiple flutes may be used. 1. Routing for Bending - General The substrate can be accurately folded by hand after a simple routing operation is done on the back skin. This fabrication method is called Rout and Return. It is unique to metal composite panel fabrication. Do not use a press brake for tight folds of the substrate. The material may be routed by using one of the two following methods Hand operated routers equipped with modified 90-105 degree V bits See figure 1 can be used effectively to remove material for folding. Table or circular saws can be equipped with a special blade See figure 2 these blades referred to as V routing blades produce very close tolerances at a much faster rate than hand routers. Figure 1 - Router Bits Commercially available wood working router bit 90 o - 105o 116 minimum Figure 2 - Routing Saw Blade V Routing blade AA 116 minimum 90o Section A-A OCTOBER 2020 20 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING Routing contd. 1a. Routing for Bending - Small Radius A very small radius can be achieved by V routing and folding. The depth of the V rout is critical. As a general guide line the exterior aluminum skin should be visible through the polyethylene core
at the valley of the rout this visual appearance should be consistent along the entire length of the rout See figure 3. Constant depth of the rout ensures a good smooth line when the fold is made. Extreme care should be taken not to score the exterior aluminum skin with the cutter. By hanging the shape of the cutter used a larger radius can be achieved. A flatter wider cut will result in a smoother bend See figure 4. Figure 3 - V Routing 90 o to 105 Interior Back Side Exterior Face Side Very small radius 164 Figure 4 - Flat Routing Larger radius Envelope Corner Cutouts INSIDE Square Corner Cutouts INSIDE OCTOBER 2020 21 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING Routing contd. 2. Making Corners An aluminum composite panel requires a grooving operation along any fold line prior to bending. This operation can be done with a custom saw blade or a customized router bit. Regardless of the tooling used the groove is commonly called a rout. The most common rout is a modified 90 V with a flattened 18 wide minimum bottom. The reason for this modification is so that the aluminum skin does not overstress during the bending process. Once correctly done this V-Rout allows the composite panel to be folded along the rout from 0 to 90easily. The term Rout and Return means that a panel has been routed and the edge returned or folded. b. A rout made with profiles other than 90 allows the substrate to be bent to various angles. These profiles eliminate fabrication problems and combine to create different joining techniques. Two additional common router profiles discussed in this document are the 135 and the Flat Rout. 2a. Flat Routed Corner a. This routed profile can be made with tooling of various widths. Once made it allows the corner to curve gently and not be as sharp as the 90 V-Rout. Flat Router Bit Saw Blade Flat Routed Dibond Corner with Flat Rout 2b. Flat Rout Distorted to Eliminate Bumps in Curved Corner The Flat Rout can also be folded anywhere within the
flat rout to create a sharp 90 bend. This sharp 90 bend is sometimes used in the fabrication of a rout and return curved corner panel to eliminate the bumps at sawed relief cuts. The panel below has a gusset for reinforcement. Distorted Flat Rout Folded 90o Rout Return Cuved Corner OCTOBER 2020 22 of 44 3ACOMPOSITESUSA.COM 800.626.3365 SECTION VI CUTTING Routing contd. 2c. Flat Rout Used to Make a Hem and Cope a. The only time a rout is set to a depth to remove the entire core material is when a Hem or Cope is needed. Both are made using a flat rout. A cope makes a support sometimes called a rabbet joint at the edge of the substrate. It is generally routed to the same width as the substrate thickness. A hem is made by first cutting a cope and then bending the remaining skin over the core material. These two flat routed conditions can be used independently or together to solve many fabrication needs. Cope at Edge of Panel Folded Cope A Hem Cope at Edge of Panel Folded Cope A Hem OCTOBER 2020 23 of 44 3ACOMPOSITESUSA.COM 800.626.3365 Routing contd. 3. 90 OCTOBER 2020 of 44 3ACOMPOSITESUSA.COM 800.626.3365
