Questions frequently asked about fabricating Formica® high pressure laminate
Question
How can bowing of composite panels be avoided?
Answer
Panels and boards faced with laminate nearly always require the reverse side to be faced with a similar material to counter-balance the effects of dimensional changes that may occur. Pre-conditioning of the substrate materials, surfacing laminates and backing laminates before they are bonded minimises the effects of differential movement caused by the materials’ reaction to changes in relative humidity. In addition, always use face and backing laminates cut from the same direction of the laminate sheet and never at right angles to each other.
(For more detail, see 'Pre-conditioning' under 'Fabrication / Preparation', and 'Counter-veneering' under 'Fabrication / Pressing', both in the ‘Technical’ section.)
Question
What are the most suitable substrates for bonding Formica laminates?
Answer
Plywood, chipboard and medium density fibreboard (MDF) are good substrate materials for fabrication. Being cellulose-based, their dimensional movement characteristics are similar to those of decorative laminates.
Certain industrial applications call for specialised substrates such as mineral boards, metal sheets, honeycomb cores and plastic foams; these require special bonding and fabrication techniques.
(For more detail, see 'Substrates' under 'Fabrication / Pressing' in the ‘Technical’ section.)
Question
What is ‘postforming’?
Answer
The term ‘postforming’ describes the process of bending decorative laminates into simple cylindrical concave or convex curves. This procedure is applied to specially developed grades of Formica laminate which retain all the properties of standard grade laminates.
On internal and external angles, curved surfaces - with their absence of visible seams - are often more aesthetically pleasing than sharp edges; they also eliminate joints in which dirt and water can accumulate.
(For more detail, see 'Machining Postformed Components' under 'Fabrication / Machining', and 'Postforming' under 'Fabrication / Edge Detail', both in the ‘Technical’ section.)
Question
How do I machine Metallic Laminate?
Answer
With the exception of F2178 (Brushed Stainless Steel), Metallic laminates can be machined and fabricated using the same standard tools, equipment and techniques as for any Formica high pressure laminate. Extra care is needed for a good quality finished appearance.
For F2178 (Brushed Stainless Steel) see the special advice in 'Machining Stainless Steel' under 'Special Products / Metallic Laminate' in the ‘Technical’ section.
(For more detail on machining Metallic laminates in general, see 'Fabrication' under 'Special Products / Metallic Laminate' in the ‘Technical’ section.)
Question
Can Metallic Laminate be postformed?
Answer
Yes. Some items in the Metallics Range are postformable, 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.
(Please check the composite availability table for Metallics under 'Product Availability’ in the ‘Specifying’ part of the ‘Technical’ section.)
Question
What substrates and adhesives are recommended for Metallic Laminate?
Answer
The nature of Metallic surface finishes (especially polished finish) demands that substrates have a high quality surface, free from undulations and imperfections.
Most adhesives can be used, 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 rippling is inevitable, it is not possible to achieve a perfect mirror finish. Good fabrication technique can minimise this optical distortion.
(For more detail, see 'Fabrication' under 'Special Products / Metallic Laminate' in the ‘Technical’ section.)
Question
What substrates and adhesives are recommended for Veneer Laminate?
Answer
Good quality MDF, chipboard and plywood with a smooth surface are recommended. Veneer Laminate should be properly press bonded to the substrate using a rigid or semi-rigid adhesive such as UF or PVA. Contact adhesives, particularly hand-applied, are not recommended. Remove any adhesive smear with a damp cloth before curing takes place. Do not use any solvents on Veneer Laminate.
(For more detail, see 'Fabrication' under 'Special Products / Veneer Laminate' in the ‘Technical’ section.)
Question
How do I fabricate Formica Solid Surfacing Material?
Answer
Specialised technical requirements apply to working with Formica Solid Surfacing in order to make the most of this versatile, high quality product. Formica appoints specially-trained companies to carry out fabrication of this material. For information on approved fabricators, please contact our Sales Department:
Tel: 0191 259 3000
Fax: 0191 258 2719
Email: sales@formica.co.uk
Question
Any there any special techniques for fabricating Formica ColorCore®?
Answer
Yes. Formica ColorCore is more brittle than standard laminates and needs particular care in handling, cutting and finishing. Please refer to full details given in 'ColorCore Laminate' under 'Special Products' in the ‘Technical’ section.
Question
How is Compact Grade cut and fixed?
Answer
Formica Compact Grade can be cut, shaped and routered using conventional carbide tipped tools and, in thicknesses of 12mm and over, it can be drilled and tapped for screw / bolt fixing.
(For more detail, see 'Fabrication' under 'Special Products / Compact Laminate' in the ‘Technical’ section.)
Question
What are the options for edging laminate-faced panels?
Answer
Panels faced with Formica laminate can be edged in a variety of ways:
• Postforming
• By self-edging using the same laminate as the face material
• With timber
• With Formica ColorCore
• With Formica Solid Surfacing
• With PVC
(For more detail, see 'Edge Treatments' under 'Fabrication / Edge Detail' in the ‘Technical’ section.)
Question
How do I avoid cracks from cut-outs?
Answer
By radiusing the internal corners, (minimum 5mm); by using rigid or semi-rigid adhesives; and by properly pre-conditioning the laminates and substrates. For full advice, please refer to 'Dimensional Movement' under 'Installation / Design Issues' in the ‘Technical’ section.
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