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.
