KommerlingUSA
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KOMACEL
Komacel Plus

Fabrication: Machining

Fabrication KOMACEL PLUS sheets can be easily and quickly worked with standard tools to process wood and metal (plastic bits and blades are required). To prevent breaking and splitting, the tools must be sharp. Generally, you should use a high cutting speed and slow, continuous forward feed, Normally, it is not necessary to cool the cutting tools, but in special cases, compressed air is sufficient. Deep notches and sharp edges can cause premature breaking of the material if too much weight is placed on the affected area.

The following machining information covers a variety of procedures. Click on the one you wish to explore.

 

 

 

Finishing

For a smooth or glossy surface, KOMACEL PLUS can be finished with buffing wheels made of felt, unbleached calico or sisal weave or felt tapes. Some enamel paints can also be used, as well as fine-grit sandpaper. To smooth uneven edges caused by sawing, drilling or milling, use a flat scraper with a grinding angle of 15°. A bondo-type material also can be used to fill any holes or cracks caused by machining. Once the bondo-type materials dry, fine-sand it to a smooth finish.

 

Sawing

To cut KOMACEL PLUS, use a high-band, jigsaw or circular saw with a cutting speed of 9,500-10,000 sq. ft./min. Depending on the thickness of the sheet, the saw blade should have a tooth space of 5 – 10 mm (3/16" - 3/8").

For Circular saws, we recommend using a tooth geometry alternating between flat and trapezoidal. The blade diameter (Y) and the tooth number (N) must be appropriate for the material, the machine type and the machine speed. To avoid rough edges and cracking, always fasten the material to minimize vibration. This is important on sheets that are 3 mm (1/8”) or less thick, both for single and compound sheets. We suggest a cutting apparatus identified for “plastics cutting.” We do not recommend using shears or a guillotine for cutting KOMACEL PLUS, as they can produce an unsatisfactory edge.

When cutting with a compass saw, use only sharpened (unset) saw blades (plastic, PVC). The feed should be manual, slow and continuous.

In some cases, it might be a good idea to consult your saw blade manufacturer. Always observe the instructions provided by the machine manufacturer.

 

Drilling

KOMACEL PLUS sheets can be worked on twist drills used for metal (DIN 1412) with 30° grooves tilted to the axle center of the drill. The center angle can be up to 110°. The back slop angle should be no less than 12 – 16°. Speed of cutting and feeding depends on the depth of the bores: the thicker the sheet, the lower the speed. For holes with a diameter larger than 20 mm (.788"), use double cutters with guide pilots. Cut holes larger than 40 mm (1.576") in diameter on circular cutters (curling drills). We recommend a cutting speed fo 150-1000 ft./min. Cutting edges must be kept sharp to prevent poor surface finish and undersized holes. High-pressure air can help remove most chips from the area.

 

Milling/Routing

Milling tools must be ground for plastics and designed to give room for a proper volume of chips. You will obtain good results working at high forward feed and moderate cutting speed with deep cuts. Router use is easy with KOMACEL PLUS when the plotter system is equipped with a special ball-headed miller and linked with suitable computer software. KOMACEL PLUS can be routered using universal, horizontal and vertical machines. KOMACEL PLUS’s close thickness tolerance makes this substrate ideal for use with this equipment. We suggest testing a small area.

 

Turning

For rough turning, we recommend combining low forward feed with a high cutting rate. The point of the turning tool should be rounded at a radius of at least 0.5 mm to keep the surface free of striation. Precision turning restricts the depth of cut to a maximum of 2 mm. At a high forward feed, the cutting speed is usually lowered to prevent the material from breaking.

 

Water Jet Cutting

This alternative cutting technique is especially suitable for contours of any degree of complexity. KOMACEL PLUS has a hard surface on both sides and a soft foam center. It is recommended that care be taken in water jet use once the outside surface is broken. It is important to test a piece prior to a production run.

 

Bolting and Screwing

KOMACEL PLUS can be affixed to most other substrates and secured with wood or plastic screws. When bolting through KOMACEL PLUS, it is recommended that it be done at least 1/4” from the edge to avoid cracking. When bolting through KOMACEL PLUS, the largest possible washer should be used to help spread the weight more evenly. When KOMACEL PLUS is used in exterior applications, bolt and screw holes should be larger than the shaft to allow for thermal expansion and contraction. Never over-tighten, as it will not allow the sheet to move and can cause damage.

 

Painting

KOMACEL PLUS is ideal for and ready to accept most vinyls, acrylic lacquers, two-part paints and automotive paints. Primers are not normally required when using PVC-compatible paints. Paints can be applied with a brush or roller. It is highly recommended to use conventional air spray equipment, as it will provide a more consistent finish. We recommend testing a small area before full production. Ink and paint recommendations can be found at the bottom of this page. Consult with the paint manufacturer to be sure the products are suitable for use with KOMACEL PLUS.

 

Other KOMACEL PLUS Fabrication Pages:

Machining
Welding
Bonding

Printing
Fixing and storage
Sheet Sizes