Sawing and Cutting Circular saw: Trapezoidal/Flat tooth blade. Flat teeth chamfered at 45°, Carbide tipped. Saw blade diameter 300mm Number of teeth 72 for cutting up to 5 panels – Leuco Ref: 188389 96 for single cuts avoiding burrs – Leuco Ref: 188390 |
Saw blade diameter 250mm Number of teeth 60 for cutting up to 5 panels – Leuco Ref: 188939 80 for single cuts avoiding burrs – Leuco Ref: 188940 Tooth Thickness: 3.2mm Clearance Angle: 15° Rake Angle: 10° positive |
Routing 2.5-4mm |
Alupanel can easily be folded by hand if a “V” shaped groove is milled on the rear of the panel. This can be done using a conventional router (available from your local DIY store) or CNC milling machine. A minimum thickness of 0.3mm of the bottom polyethylene must be left on the bottom/back of the decorative face. Cutting speed: 3000 – 5000 m/min Feed speed: 25 – 30 m/min |
Slotting |
Grooves can also be easily cut using a special cutting machine that comes complete with a guide/jig . The “V” shaped groove is automatically cut into Alupanel, which can then be easily folded by hand. |
Drilling
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Alupanel is easily drilled – we suggest for best results, the use of bits designed for drilling aluminium and plastic are used. For large holes, a drill bit with a locating point is required. Cutting Angle: 100° - 140° Helix Angle: 30° - 50° Cutting Speed: 50 – 300 m/min Feed Speed: 0.02 – 0.5mm/revolution Hole Size: Screw width + 2mm |
Bending with a Panel Folder |
Use a folding table. Min inside radius R=15xt (t=panel thickness) |
Bending with a 3 roller panel bender |
3-Roller panel bender is preferable for bending large internal diameters. |
Clamping and Bolting |
Can be clamped with a serrated corner joint and butt sections for Alupanel thickness of 3mm and 4mm. When bolting, e=2D is the formula to use to calculate the distance of fixing to the end of the panel. |
Shearing |
Use a standard guillotine for this purpose. Ensure the top cover sheet is inserted properly. |
Hot Air Welding |
A polyethylene welding rod is available for use with an electric hot air welding set. |
Spray Painting and Coating |
Standard air drying painting acrylic or two part polyurethane coatings are suitable. |
Riveting |
With the usual equipment using rivets or blind rivets. For external use please take thermal expansion into account. Hole size = Rivet Width + 2mm |
Folding |
Alupanel can easily be folded by slotting or routing a groove on the rear of the product, as described in the slotting and routing section. |
Laminating and Photo MountingAlupanel can be laminated manually orby machine using cast or calendared self adhesive foil. The quality of polyester finish ensures it does not come off if the foil is changed. Photographs and images can be applied with adhesive film or wet dispersion adhesive. Panels must be clean and free from grease. |
Screen + Digital PrintingThere have been numerous inks testedfor compatibility and adherence to Alupanel. The use of water based inks is not advisable. Please pre-test a small area with the ink to ensure suitability of use with Alupanel. |
Smoothing EdgesAfter cutting Alupanel, any rough edgesand burrs ,ay be removed using a file with a rasp like effect. Always file along the length of the panel. |
PunchingUse a steel band tool on a punchingbase for 2mm and 3mm thickness. Conventional punching machines are excellent for this process. |
Applying Vinyl Letters and SheetEnsure panels are clean and free fromgrease. The application of vinyl is prefect for Alupanel. The smooth flat surface combined with the dimensional stability enure a quality finish that will last. |
GluingUse standard metal aluminium adhesives. Ensure you avoid contact with the polyethylene centre, some adhesives will attack and decay the core. The use of conventional double faced tapes is acceptable. |