Wednesday, September 11, 2013

Scratch Resistance of 3D Laminates

Manufacturers of 3D Laminates know that the product has many advantages as compared with HPL and other surfaces. 3DL's impact resistance can be far superior to most laminate surfaces and the taber abrasion can be extremely high especially with solid colors whitch are homogeneous. But how about scratch resistance? In this article I'd like to discuss some obscure tricks on how scratch resistance is obtained with 3DL that most companies don't share.

Firstly, each company has claims that their product is more durable based upon a unique or proprietary lacquer. Although each company has its own formulation the real secret is in tweaking a combination of lacquer and texture. Also gloss level of the print layer and lacquers can play a roll as well as the color of the print however this article is meant to focus on a specific subject of texture which is one of the biggest factors that contribute to scratch resistance of 3DL.

OK... so to start....
The most common lacquers are polyurethanes or polyurethane combinations. Applying lacquer is key to protect the top surface's hills and valleys and provide hardness to the surface. This sounds like the end all be all solution however in reality if a sharp objects digs into the peaks (hill tops of the texture) in a certain way then its irrelevant as to how much or what type top coat is applied. Think of your carpet and running your foot over the carpet. The carpet is not damaged however you moved the carpet strands in a different direction it gives the appearance of difference and that is at the basis of what a surface scratch really is. So if you think about it, a micro level, scratches to most surfaces are either a displacing or a removing of surface area. In theory a top coat will protect a scratch from occurring however in practice its only one component to creating a scratch resistant surface.

In general a higher texture combined with lacquer is a way to get an overall scratch resistant surface. Some woodgrain designs, for example may have a lighter texture from one supplier due to market demand and when you try to scratch it, the appearance is that that supplier's product is less scratch resistant however upon closer inspection you may find that if they put the same texture on they would get equal scratch performance. So its very difficult to judge scratch resistance between supplier if you are not measuring apples to apples. Since each supplier uses different textures and different lacquer/gloss level combos it also may impact the scratch resistance performance in that single color.

Another point is in the texture layout. Imagine a texture on a microscopic level and when a sharp object moves in a straight line it is removing hills on the tops of the texture. If the texture is spaced in a certain way to make the hill tops more random it can trick the eye into not seeing the scratches as easily.  This can also be achieved by making different heights of texture in the emboss. Imagine at certain pressure points only knocking off a certain height of textures however with just slight more pressure it may finally break into the next layer of texture hills. Its another clever way to enable an object to glide across the top of the texture yet not see the scratch as easily with the naked eye. Surprised by this observation? As with any product, the expertise in product design combined with the marketability of its appearance all come into play in order to achieve a result. You may in fact, start to see all the complexity that goes into creating a 3DL.

You will also notice that dark colors show scratches more easily. Lighter colors absorb the light and blind your eyes to the scratches that are on the surface so to speak.

So, in conclusion,  there are a variety of ways to make a scratch resistant 3DL... Lacquer, quantity of texture, color of design and texture layout on the microscopic level. The items just mentioned must also be used in proper combos to create the best affect.

Saturday, May 4, 2013

Ways to process 3D laminates, brands of membrane presses for thermofoil

There are various ways to process 3D Laminates. In this article I will mention all the ways you can process 3D Laminates and also mention some common machine names used in membrane pressing and vacuum pressing.

MEMBRANE PRESSES:
At the time of me writing this article, the most common brands of membrane presses in North America are Wemhoner which is sold by Stiles Machinery, Shaw Almex which is sold by Black Brothers, Italpress which has their own office, Orma, and Burkle.

Advantages of membrane presses: Membrane presses typically use rubber or silicone membranes to firstly transfer heat to the components more rapidly and secondly they apply positive pressure on top of the components to press the material while the vacuum on the bottom of the press can also have suction. The pros are that the cycle times are fast and its easier to get more detail in the component under most conditions. The cons are that they membranes need to be replaced periodically depending upon the cycles ran and also based upon the parts produced. The other con would be the cost of a membrane press. They typically cost $200K to over $500K however you may find one for less or a used one. Please do keep in mind that some membrane presses are capable of removing the membrane  from the machine and still operating but not all.

VACUUM PRESSES:
The most common brands of vacuum presses sold in North America are Shaw Almex, Italpress and Greco. If you are a maker of vacuum presses and do not see your company's info here please contact me. I apologize if I overlooked it.

Advantages of vacuum presses: Vacuum presses are more affordable however they do not have positive pressure on top. Vacuum presses rely solely on the vacuum power below and they use light bulbs or heat plates on top in some machines. Most vacuum presses have longer press cycle times and do not get as much detail into the components. There are some tricks such as drilling holes in the backs of the components to enable vacuum to pull through the MDF and also some companies will score the glue line on the side of the component with a knife which breaks the seal a bit and enables more vacuum. In general, companies who produce mass components for others prefer a positive pressure membrane press with or without the membrane in lieu of a vacuum press. Vacuum presses are an inexpensive way to get in the business however they are more suited for companies who use the components internally for their own cabinets or fixtures and less suitable for companies who mass produce components for others and whose livelihood is attached to selling components due to the longer press cycle times.

FLAT LAMINATION:
3D Laminates or vinyls can also be flat laminated either by a flat lamination machine utilizing PUR adhesive typically. These machines are designed for fast flat lamination. The other way to flat laminate is by a nip roller using a 2 part epoxy glue.

PROFILE WRAPPING
3D Laminates can also be processed by profile wrapping moldings

MITER FOLDING
Miter folding is where material is flat laminated or membrane pressed to a component with a v groove in the back of the part. A line of glue can be ran in the groove and then the part is simply folded to create a seamless fold. The vinyl acts as a hinge. Please note that white lines can appear on the fold with vinyls which is caused by various reasons. Companies use wooden blocks to rub or heat guns to remove the white lines. Some laminate manufacturers can produce vinyl so that they will not whiten when folded.

HAND LAMINATION:
3D Laminates can be processed by contact cement, peel stick or laminate backed for hand applications. The laminates are not specifically made for this type application so this is the exception rather than the rule.

CONCLUSION:
This post is just a teaser and does not get deep into the topics. If your company is a processor in North America and has technical questions you can contact me for more detailed information, tips and tricks.




































Monday, April 15, 2013

How to produce shaker doors with 3D Laminates

Producing Shaker doors that are clean and neat are the goal. If you take a 3D Laminate shaker door and cut it open you may be surprised to find a plant in center panel. Read below to learn more.

PRODUCING A SHAKER DOOR:
To produce a shaker door and then membrane or vacuum press the door companies first router out the center reveal. One common issue is that in doing so the fibers of the door open up. It can be very difficult to then get a sander in and to accomplish the desired finish. On top of that , when a PUD adhesive is applie, the PUD adhesive is about 58% water which further opens the pours of the MDF open and will show through the 3D Laminate after pressing.

The ideal solution is to take a 1/8" HDF  board cut to the size of the center panel and to drop it into the center of the shaker. This is the most common way companies create good looking shaker doors in the component industry. The HDF (High Density Fiberboard) can be left unsanded with the factory finish. It is important however to glue the center panel in because failure to do so will make it sound like the beat of a drum when closing the cabinet door. The center of the door can be glued in by the PUD adhesive used in the membrane pressing process.

PAINTED DOORS:
For painted doors, the key to get a good finish is to paint the door and then sand it to a 250 to 300 grit and then paint again. This will smooth out the surface before doing a finishing coat.

PLANT ON SHAKER:
For plant on Shaker, you can take 1/2" mdf and run a 1/4" to 1/4" mdf through a shaper and then miter cut and piece the parts on the door using a PUR adhesive. This reduces the milling time out of the shaker and creates a lower processed cost Shaker. It will have a reveal line on the perimeter of the door however this is a small price to pay for saved CNC milling time.

CONCLUSION:
If you follow the steps above you can get a better looking shaker door. For additional information please feel free to contact me for further information or further research.

Tuesday, February 12, 2013

Ways to apply or use 3D Laminates

I often get companies who ask how they can apply 3D Laminates (3DL) if they do not have a membrane or vacuum press. I'd like to explain the strengths and weaknesses of 3D Laminates as well as why you should have a relationship with a component maker.

Firstly, 3D Laminates are primarily made out of PVC. The average guage is 0.3mm or 12 mil however the product can be as thin for membrane pressing as 0.2mm (10mil) up to 0.7mm (28 mil). The product comes on rolls wrapped on a 3" core. Typically one can buy by the linear yard so its possible to get small quantities shipped all over North America by UPS or Fedex. The width of the product ranges between 1420 (56") and 1450mm (57") with the print being 53" to 57". The reason the print does not always go to the end depends on the gravure printing cylinder used to print the color. Since a membrane press has gaskets that average around 56" the outside edges are typically waste.

STRENGTHS OF 3DL: They have much higher impact resistance than typical High Pressure Laminates, elleviate the need for edgebanding, can be contoured to create unique surfaces and in solid colors are homogeneous and so will have much higher taber abrasion. 3DL is a perfect solution for design in that it brings in texture and color seamlessly.

Below are the various application techniques:
MEMBRANE PRESS (POSITIVE PRESSURE): Typically membrane presses use a silicone or rubber membrane to push the 3DL down onto MDF. Many Kitchen and Furniture manufacturers outsource production to companies who have CNCs and expensive Membrane Presses because they take the labor out of producing custom size components. Membrane Presses cost between $150K to $500K on average and the advantage of the finished product is that the edgebanding is eliminated from the sides since the material forms on all the sides but the back. The MDF used has a melamine back that counterbalances the product to create a stable end product. Note that some presses can be operated with air pressure to function in lieu of the membrane and they have positive pressure on top as well as suction from the bottom.

VACUUM PRESS (NEGATIVE PRESSURE): Vacuum presses that only use negative pressure vacuum out the air forming the material down onto the MDF. The heat is delivered by light bulb rather than by membrane. Some vacuum presses have heat plates on top however they are the exception. The benefit of a vacuum press is their low cost. The average cost is $50,000 however used ones can be found for significantly less. The weakness of a vacuum press is that complex profiles routered in may be more difficult to achieve and this can force producers to drill their cup holes or to drill a small hole in the back to penetrate the melamine surface to enable vacuum to pull through the MDF. Vacuum presses are more suited to simple doors as well as low volume producers. There are some exceptions of producers who make their parts internally for their own cabinets or fixtures however for a company wishing to getting into producing components for a living the longer cycles of the vacuum press make the machine a bit inefficient.

FLAT LAMINATOR: 3D Laminates can be applied using a flat lamination machine onto steel, MDF and other substrates. For MDF, typically PUR adhesive is used and beautiful panels can be created however the finish product is 2D as the material cannot be formed on the sides. When the product is flat laminated the product can be used for large panels in a Kitchen, for walls and other applications that need larger panels. It is possible to membrane press a large panel however a flat lamination machine is faster and there are less chances of wrinkles. When membrane pressing large panels controlling wrinkles and rejects can be challenging. Some companies use flat lamination machines for High Gloss to get a more mirror finish. The reason is that when applying heat and pressure High Gloss 3DL can develop orange peel or show imperfections in the substrate. When flat laminating however, the material can be rolled on so as to float onto the substrate rather than form into the substrate.

PINCH ROLLED: Pinch or Nip rollers are cold application laminators. These are essentially two rubber rollers and you apply tension to the rollers via a crank or electronic. The machines are typically cold and just used to laminate the material onto the substrate. Unlike a flat laminator, free standing pinch rollers do not have a glue application station so one must apply glue in a glue spreading machine or by rolling out a 2 part Epoxy glue by foam roller. To get high quality High Gloss panels however, a glue spreader is the preferred machine.

PROFILE WRAPPED: Profile wrapping is most used to make mouldings. The material is fed through a series of rollers and each roller can be set at a different angle to create complex moulding or to wrap around the back of the part. The substrate is either a plastic composite foam or mdf. The advantage of this machine is the speed and reduced scrap however profile wrapping is a skill best outsourced to a professional company just like membrane pressing.

HAND APPLIED: Companies ask all the time if they can buy our material to laminate by hand. We can sell the material in small quantity however unlike HPL which has a rigid back, cut on the table saw and routered, the raw 3DL should be cut with a knife. Contact cement can be used to apply the product to substrates such as particle board or MDF however one must note that the substrate should be smooth. Small refacers can apply the product to the cabinet sides by hand however the product is more meant for professional processors and not meant for hand work. If the product was laminated by hand one should take care to where the seams will show since it cannot be routered and therefore edges cannot be burnished smooth to keep the edges from being caught and pulled up by a shirt sleeve, etc.

PHENOLIC BACKED 3D LAMINATE (PB3DL): Some companies take 3DL and laminate to phenolic. This is more expensive than HPL however the color, texture and beauty can be a driving force behind wanting a 3DL with a phenolic back. Typically the material is applied by a pinch roller or flat lamination machine using a 2 part Epoxy or PUR to get a solid bond. Once the material is laminated to phenolic it is easier to handle however you will still have to edgeband and to deal with the brown phenolic lines that can show up with typical HPL. When possible its best to use membrane pressed parts and use PB3DL just for filler pieces or cabinet sides. In cases where panels are trying to be created for walls by hand however, PB3DL can be a good option to get the beauty however to have flexibility on the jobsite.

PEEL STICK: 3DL backed with peel stick is another option. This gives the product a peel back and makes the product apply to clean, dry, smooth substrates by pressure sensitive adhesive. The product can be used by refacers however one must have specific skill to use a Peel Stick 3DL because if the substrate was not clean it can delaminate. Also if the proper bevil was not put on a cut and the material sticks out slightly a shirt sleeve can catch and cause the product to peel up. Peel stick is perfect for tradeshow booths, refurbishment and especially for panels which will be hidden behind t moulding or corner moulding where the edges cannot come up. Peel stick is applied using a slitter and then a peel stick lamination machine. This is common in the sign industry and the material function similar to a nip roller in its application however it has a separate rewind station for winding up one side of the release paper.

EDGEBANDING: Although technically you can strip 3DL into the width of edgebanding and technically it can be used, it should be noted that 3DL is meant to stretch so when applying glue on an edgebander and the metal tip coming into contact with the 3DL transfers a high heat through the conductive metal and can stretch out the 3DL. So some companies have used 3DL by adjusting the tip away from the material and when the glue flows hot it adheres but does not transfer the heat from the tip in a way that activates the 3DL to overstretch. Typically edgebanding is produced in a way which the core plastic does not stretch and this is done by having different compounds. If you would like edgebanding that is an exact match you can ask your 3DL supplier and in some cases they may be able to make it however in most cases they will refer you to an edgebanding company that focuses on the production of edgebanding.

CONCLUSION:
In conclusion, 3D Laminates are very versatile and although they are less known and used than typical High Pressure Laminates, they have unique properties that make them durable and appealing. 3D Laminates are unique in their ability for form and the production capabilities with 3D Laminates make them an ideal product for specification. Finally, since 3D Laminates are more of a niche when compared to High Pressure Laminates they are ideal for projects and in applications where custom colors are needed.