All the general recommendations for fabricating thin laminates apply to Formica® Compact laminates; treat these in the same manner as double sided composite boards. Please observe the following additional recommendations.
General
The greater thickness of Compact Grade laminates imposes greater demands on cutting tools and causes greater wear. Slower feed speeds are required. The degree of feed speed reduction depends on the thickness of the laminate and the quality of finish required. Consult tool manufacturers as to the type and quality of tungsten carbide tipping needed to provide the best performance. For long production runs, and where a high quality finish is required, consider PCD (Polycrystalline Diamond) tooling.
In all machine processes, avoid localised heating caused by poorly maintained saws and cutters.
For optimum flatness, cut the longest dimension of the panel to coincide with the longest dimension of the Compact Grade sheet.
Sawing
Saw blades normally used for cutting double sided composites are generally suitable for cutting Compact Grade laminates. Saws of less than 2mm in thickness are not recommended.
Break-out on the underside of Compact Grade sheets can be reduced by various methods:
• using a pre-scoring blade on the underside;
• using a base-board of plywood or hardboard beneath the sheet;
• altering the exit angle of the saw blade by adjusting the height setting.
Note
The higher the saw blade, the better the top cut and the worse the bottom cut; and vice versa.
When sawing Compact Grade laminates with two decorative faces, the feed speed essentially governs the quality of the saw cut. A speed of between 0.03mm and 0.05mm per saw tooth has been found to be the most successful.
Profile Cutting and Edge Finishing
It is not necessary to apply edging strips or edge sealants to Compact Grade panels, and for many applications clean sawn edges are sufficient.
To achieve a superior finish or a profiled edge, use a spindle moulder or router. For this type of work PCD tooling is recommended. It is not possible completely to avoid cutter marks, but they can be minimised by feeding the work at a constant controlled speed with a mechanical power feed. Take care to avoid pausing during cutting and profiling, as burn marks which are difficult to remove may result. Where edges must be completely free from cutter marks, carry out a further sanding and scraping operation. Buffing with steel wool and applying silicone free oil enhances edges.
Chamfering or profiling the edges of Compact Grade panels reduces the risk of edge impact damage.
Drilling
The most suitable drills for use on Compact Grade laminates are those designed for plastic sheet materials. These drills have a point angle of 60° - 80° instead of the normal 120° for drilling metal.
To avoid break-out on the reverse side, gradually reduce the feed speed of the drilling head and the pressure applied when approaching the point of breakthrough. Working on a firm underlay, such as plywood or chipboard, also reduces the risk of break-out.
For blind boring into the face, the depth of the hole should be such that at least 1.5mm of material remains between the bottom of the hole and the other side of the sheet. TCT lip and spur drills produce clean flat-bottomed blind holes, with less risk of point penetration on the reverse side. This allows maximum depth of material to be used for fixings. Compact Grade sheets less than 10mm thick are not suitable for blind fixing.
When drilling parallel to the surface (edge drilling) at least 3mm of material must remain on either side of the hole. Threaded holes can be produced using engineer’s screw cutting taps. Self-tapping screws or threaded brass inserts may also be used.
Postformed Corners
Internal and external postformed Compact Grade corners can be produced to a minimum radius of 15mm and a maximum girth of 300mm. For details, check with our Fabrication Support Unit: Tel: 0191 259 3411
Fax: 0191 296 3397
Email: fsu@formica.co.uk
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