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With the exception of F2178 (Brushed Stainless Steel), Metallic Laminate can be machined and fabricated using the same standard tools, equipment and techniques as for any Formica® decorative laminate. Extra care is needed for a good quality finished appearance.
During fabrication and installation ensure that the sheets are all in the same running direction (as indicated on the protective coating), since variations in appearance can occur if sheets or panels are rotated through 90˚ or 180˚ in relation to each other.
Sheets with linear features may need a dressing cut to properly align and position the feature relative to the edge.
Substrates and Adhesives
The nature of Metallic Laminate surface finishes (especially polished finish) demands that substrates have a high quality surface, free from undulations and imperfections.
Most adhesives can be used for Metallic Laminates, except for those based on urea (UF and MUF types).
To avoid surface distortion, spread adhesives evenly and free from inclusions. With polished finishes, best results are achieved using adhesives with low shrinkage (such as PVA) to minimise telegraphing.
Because some surface ripple is inevitable, it is not possible to achieve a perfect mirror finish. Good fabrication technique can minimise this optical distortion.
Forming
Cold Bending
As a general rule, Metallic Laminate strips in widths of up to 60mm can be cold bent to a radius of 200mm. It is possible to cold bend wider strips but considerable force is required; in addition to adhesive, the laminate must be fixed back with a metal section or capping strip to prevent spring-back.
Postforming
Some Metallic Laminate items are available in postforming grade, identified by the letters PF printed on the protective coating. These laminates can be formed in the temperature range 120˚C - 130˚C, using normal static or continuous postforming machines. The recommended minimum forming radius is 12mm, though tighter bends can be achieved depending on equipment and technique.
Pressing
Metallic Laminates should be press bonded to achieve optimum aesthetic appearance.
Cold or hot pressing (60˚C maximum) can be used, at a pressure of 10N/cm2 - 30N/cm2 (14psi - 43psi). Press platens and nip rollers must be clean. Smooth down any creases in the protective coating before pressing. When pressing embossed laminates, use suitable padding to obtain uniform pressure. Remove any glue spillage immediately with warm water and a damp cloth.
Counter-veneering
The following table summarises the recommended balancers for Metallic laminates.
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Metallic Laminate
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Category A
Opimum Flatness
(Better than BS 4965
limit)
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Category B
Flatness meeting
BS 4965 limit
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Category C
Sealing purposes only:
flatness not guaranteed
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Polished Chrome
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Laminate identical to that of face laminate
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MBC Polished Chrome Balancer
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Universal Backing Board
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Other Polished Finishes
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MBP Polished Metallic Balancer
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Matt and Brushed
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MBM Matt Metallic Balancer
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Embossed Aluminum
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MBAE Embossed Copper Balancer
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Embossed Copper
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MBCE Embossed Copper Balancer
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F1278 Stainless Steel
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Stainless Steel Balancer
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F4109 Alu Cubic
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MBC Polished Chrome Balancer
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F4587 Birch Cubic
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MBP Polished Metal Balancer
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Do not use melamine-surfaced laminates to balance Metallic Laminate.
For optimum flatness use the same laminate on both sides (Category A).
Flatness meeting BS 4965 requirements (1mm maximum distortion over 600mm length) can be achieved using the corresponding metallic balancer (Category B).
For small panels, or where flatness is less important, a phenolic laminate backing board may be used (Category C).
Carry out pre-conditioning as for normal laminates.
Finishing
Edges may be trimmed in the normal manner and any burrs can be removed with a fine file, always working towards the laminate surface. Corners of internal cut-outs must be radiused and free from chipping.
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