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3A Gator® Heavy-Duty Foam Board Family Fabrication Manual

EXTERIOR The Heavy-Duty Foam Board Family Fabrication Manual 3A Composites August 2013 1 Foreword Thank you for choosing a 3A Composites product for your graphic display applications. EXTERIOR We have compiled this Fabrication Manual based on our Fabrication Guide which is divided into the following sections Mounting Repositioning Vinyl Direct Digital Printing Direct Screen Printing Painting Knife Cutting Saw Cutting Routing Die Cutting Punching Embossing Forming Curves Appendix I MSDS Material Data Safety Sheet Appendix II Specifications 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 forconsistency 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 ofContents. An Appendix III section lists products that can be used in conjunction with 3A Composites products. 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 and selecting the document library. 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. 3A Composites August 2013 2 Table of Contents EXTERIOR Table of Contents.... 3 Introduction 3A Composites Family of Products .5 Choosing Your Graphic Display Board .9 Introduction to Gator 10 Why Choose Gatorblanks 10 Why Choose Gatorplast . . 10 Why Choose Gatorfoam 10 Gator Application Fabrication Guides . 11 Section I Mounting Mounting General Notes 12 A Note on Archival Mounting Conservation Framing .12 Methods for Mounting 12 Surface Preparation .12 Other Considerations .13 Hot Mounting General Notes 13 Cold Mounting General Notes 13 Getting Good Adhesion . 13 Demounting Bad Mounts 14 Avoiding Wrinkles and Surface Blemishes 14 Clear Overlays .14 Cold Mounting Procedures 14 Cold Mounting by Hand Using Transfer Adhesive 14 Cold Mounting by Hand or Press Using Spray Adhesive 15 Cold Mounting by Roller Laminator with an Adhesive-backed Graphic 15 A Note on Cold Mounting Non-Porous Graphics .15 A Note on Cold Mounting Porous Graphics 16 A Note on Cold Mounting with Pressure Sensitive Tapes 16 Section II Repositioning Vinyl Vinyl General Notes 17 Surface Preparation . 17 Repositioning the Vinyl . 17 Section III Direct Digital Printing Direct Digital Printing General Notes 18 Surface Preparation .18 Suitable Inks 18 Section IV Direct Screen Printing Direct Screen Printing General Notes .19 Surface Preparation . 19 Suitable Inks 19 Ink Curing . 19 3A Composites August 2013 3 Table of Contents EXTERIOR Section V Painting Painting General Notes . 20 Surface Preparation

.20 Suitable Paints 20 Application . 20 Drying 20 Section VI Cutting Cutting General Notes . 21 Knife Cutting Knife Cutting . 21 Shearing Shearing 21 Saw Cutting Saw Cutting 21 Routing Routing .21 Die Cutting Punching Die CuttingPunching .21 Steel Rule Die Cutting Process 22 Press Considerations . 22 Steel Rule Considerations . 23 StrippersEjectors 23 Section VII Embossing Embossing .24 Section VIII Forming Curves Forming Curves 24 Appendix I MSDS Material Safety Data Sheet 25 Appendix II Specifications Adhesives . 25 Fastening . 25 Storage Guidelines 25 Gator Physical Product Specifications Chart 26 3A Composites August 2013 4 A Composites Family of Products EXTERIOR CHOOSING YOUR GRAPHIC DISPLAY BOARD IS EASIER THAN EVER. 3A Composites offers a legendary array of brands for the graphic display market including fluted polypropylene sheets paper-faced foam boards expanded plastic boards polystyrene foam boards with wood-fiber veneers and aluminum composite panels. All of our brands offer unique competitive advantages and outstanding capabilities for designers and fabricators seekingto create signage displays and graphic applications on an epic scale. THE PAPER-FACED FOAM BOARD FAMILY Fome-Cor Board is the industrys leading paper-faced foam board for more than 40 years. It is comprised of extruded polystyrene foam with clay-coated white or black paper facers. Fome-Cor ValuBoard is comprised of extruded polystyrene foam with natural kraft facers. Fome-Cor Acid-Free is comprised of extruded polystyrene foam with acid-free paper facers that meet Library of Congress standards for conservation framing. Fome-Cor Self-Adhesive is comprised of extruded polystyrene foam with clay-coated paper facers one of which is covered with press

ure sensitive adhesive. Simply peel back the release facer as you position the graphic on the sticky surface. Fome-Cor Heat-Activated is comprised of extruded polystyrene foam with clay-coated paper facers one of which is covered with heat-activated adhesive. Fome-Cor JetMount is comprised of denser extruded polystyrene foam with clay-coated paper facers. Foam-X Recovery is comprised of memory retaining polystyrene foam with clay-coated paper facers. WHY CHOOSE FOME-COR The original graphic arts foam board with a great reputation for performance Perfect for die cutting with a compressed edge that stays closed Quick service on cut-to-size orders including large sheets up to 8x10 Uniquely embossable for 3-D effect displays Cuts easily and cleanly even by hand Extremely lightweight Well-suited for screen printing or digital direct printing applications 316 Extruded Polystyrene Core in White or Black White Clay-Coated Facer over Black Non-Coated Facer Kraft Non-Coated Paper White Clay-Coated Facers Black Non-Coated Facers 316 Extruded Polystyrene Foam 38 316 18 Extruded Polystyrene Foam WHY CHOOSE FOME-COR VALUEBOARD A cost-effective alternative to corrugated cardboard Provides a smooth surface for mounting with no flute marks 3A Composites August 2013 High-Tack Adhesive Coating under Red Release Facer 18 Extruded Polystyrene Foam Clay-Coated Facers WHY CHOOSE FOME-COR ACID FREE Perfect for the archival preservation of valuable art and photographs No additional backing is required saving time and framing materials ValuBoard Fome-Cor Board Crme Conservation Facers 316 Extruded Polystyrene Foam Acid-Free 316 Extruded Polystyrene Foam Low-Tack Adhesive Coating under Blue Release Facer Self-Adhesive 5 3A Composites Family of Products EXTERIOR WHY CHOOSE FOME-COR SELF-ADHESIVE Eliminates the use of pressure-sensitive adhesive stock Available in repositionable Low-Tack LT or immediate bonding High-Tack HT HT identified by red release facer and LT identified

by blue release facer WHY CHOOSE FOME-COR HEAT-ACTIVATED Eliminates the use of hot melt tissue stock The adhesive is activated with low temperature settings for a quick damagefree mount Can be used on a heated mechanical or vacuum dry mountpress or with a heated roller laminator WHY CHOOSE FOME-COR JETMOUNT The denser foam core provides increased rigidity and warp resistance Great for more demanding mounting jobs for display signage and framing Heat-Activated Adhesive Clay-Coated Facers 316 Extruded Polystyrene Foam Heat-Activated White Clay-Coated Facers Black Non-Coated Facers 14 Enhanced Polystyrene Foam JetMount WHY CHOOSE FOAM-X RECOVERY Clay-Coated Paper Facer Memory core resists denting Edges remain open when die cut Economical alternative to competitive foam boards 316 Extruded Polystyrene Foam Foam-X Recovery THE FOAMED PVC FAMILY Sintra has been the industrys leading PVC for more than 20 years. It is comprised of moderately expanded closed-cell polyvinyl chloride PVC in a homogenous sheet with a low-gloss matte finish. e-pvc is a low-density lighter and less rigid expanded PVC board. WHY CHOOSE SINTRA Sintra Bright White is now the brightest and whitest PVC board on the market The trusted brand leader by which all others are measured Lightweight yet rigid and durable Easily formed into just about any shape imaginable using wood and foam board fabrication techniques Heat formable and chemical resistant WHY CHOOSE e-pvc Economical PVC alternative for less-demanding applications Satin Finish 3A Composites August 2013 Expanded Rigid Homogeneous PVC 6 3A Composites Family of Products EXTERIOR THE HEAVY-DUTY FOAM BOARD FAMILY Gatorfoam is the industrys leading heavy-duty foam board for more than 30 years. It is comprised of extruded polystyrene foam bonded between two layers of wood-fiber veneer. Gatorplast is comprised of extruded polystyrene foam bonded between two layers of high-impact polystyrene cap sheets. Gatorblanks are thick panels o

f extruded polystyrene foam with no facers. WHY CHOOSE GATORFOAM The original heavy-duty graphic arts board Excellent reputation for digital and screenprinting New Bright White facer is the brightest board of its kind Dent and scratch resistant WHY CHOOSE GATORPLAST Smooth high-impact liners resist warping Lightweight and water-resistant Vinyl graphics are repositionable WHY CHOOSE GATORBLANKS Perfect for signs displays and dramatic in-store lettering Lightweight yet durable and easy to cut and form 316 Durable Polystyrene Foam High-Impact Polystyrene Facers Various Wood-Fiber Veneers Gatorfoam 3A Composites August 2013 12 Durable Polystyrene Foam Durable Polystyrene Foam Gatorfoam Exterior Gatorplast 1 Black Polystyrene Surface 1 White Polystyrene Surface Gatorblanks 7 3A Composites Family of Products EXTERIOR THE ALUMINUM COMPOSITE MATERIAL ACM FAMILY Dibond has been the industrys leading ACM for more than 15 years. It is comprised of two pre-painted sheets of .012 aluminum with a solid polyethylene core. e-panel is comprised of two pre-painted sheets of .008 aluminum with a solid polyethylene core and manufactured in China. WHY CHOOSE DIBOND 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 WHY CHOOSE e-panel Recommended for flat panel applications Coil-Coated Paint or Brushed Metal Finishes Aluminum Facers 3A Composites August 2013 Polyethylene Core 8 Choosing Your Graphic Display Board EXTERIOR Application Guide Fome-Cor ValuBoard Fome-Cor Board Foam-X Recovery Fome-Cor Acid-Free Fome-Cor Self-Adhesive HT Fome-Cor Self-Adhesive LT Fome-Cor Heat-Activated Fome-Cor JetMount e-pvc Sintra FiberMate Gatorblanks Gatorplast Gatorfoam Gatorfoam Exterior e-panel Dibond 3A Composite

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