Tips and Guidelines

Machining of Acryform | Commonly asked Questions Drilling | Tapping | Sawing | Line Bending | Laser Cutting   Machining of Acryform  Acryform has a thermal expansion coefficient some ten (10) times higher than metals. As a result more heat is generated during machining than with metals. Adequate tool clearances must be provided to minimise heating. Allowing frictional heat to build up causes gumming, discolouration, poor tolerance control and rough finishes. When fitting Acryform to frames, it is important to allow for the natural moulded texture of the sheet. Acryform is subject to expansion and contraction movement. It has a expansion co-efficient ten times that of steel. Ensure that all fixing holes are drilled "over-size" to prevent expansion cracking. Each panel is formed with a smooth surface (but not flat) on one side and a textured surface on the opposite side. The edges remain saw cut unless polished edges are requested. Drilling: Drills of high speed steel or premium high speed steel are recommended, with low helix angles, point angles of 110 - 120 degrees, and wide, highly polished flutes to ease chip exit. Normal feed rates are in the range of 0.001-0.0012"/rev for holes of 1/16"-2" diameter. A point angle of 120 degrees should be used for Acryform. This is considerably less than the normal 60-90 degree point angle on "standard" steel drill bits. If using "standard" drill bits, the lower point angle can cause the drill bit to "bite", which may impose severe loading of the work-piece, resulting in cracking or other damage. Clearance angles of 12-20 degrees are usually sufficient to prevent the drill flanks from rubbing in the bottom of the hole. Tests may needed to determine the drill diameter for accurately sized holes, taking thermal expansion and elastic recovery into account. Pilot holes are not necessary, except when the hole is to be reamed or counter-bored. Peck feeds to remove chips and compressed air cooling may be needed for deep holes through thick Acryform sheets. Circle cutters are often preferred for holes on thin Acryform. Use aqueous solutions for deep drilling because metal cutting fluids and oils may degrade or attack the chemical composition of Acryform and may cause a cleaning problem. Hold Acryform® firmly during drilling to counter the tendency for the tooling to grab and spin the work. Return to the top of the page Tapping: For tapping of through holes in Acryform sheet, a speed of 50 ft/min is appropriate. This speed should be reduced for deep or blind holes, and when the percentage of thread is greater than 65-70 percent. Taps should be of molybdenum high-speed steel, with finish ground and polished flutes. Two-flute taps are recommended for holes up to 0.125" diameter. The danger of re-tapping on the return stroke can be reduced by blunting the withdrawal edges of the tool. Return to the top of the page Sawing: Circular, band or jigsaws may be used for sawing Acryform sheet. Circular saws provide smoother cut faces than band or jigsaws, but band saws run cooler, so are often preferred even for straight cuts. Saws should have skip teeth or buttress teeth with zero front rake and a raker set. Precision tooth saw blades should be used for thicknesses up to 1". Dull edges to the teeth cause chipping of Acryform and may cause breakage of the saw. Return to the top of the page Line Bending: Acryform can also be line bent. An experienced thermoforming fabricator best performs this. The flame polished edge gives the illusion of green edged glass Laser Cutting: Laser cutting your custom designs provides the added bonus of polished edges whilst cutting. This gives added cost savings in the fabrication stage.   Commonly Asked Questions When installing which side should be used? Depending on your needs and personal preference, the textured side optically reflects the texture more intensely. If cleaning is an issue the smooth is ideal. How do we install Acryform? In the same way as any other sheeting or paneling. Does Acryform conform to safety standards? Acryform is approved under the following Safety Standards. Flammability Standard 94HB; ANSI Z97. 1-1972, Safety glazing material used in Buildings. How do I light Acryform for maximum effect?Edge lighting is the most effective emphasising the natural textures. Illumination by halogen lamps on an oblique angle to the panel is also very effective. Used as a lighting panel, Acryform is best sandblasted for greatest diffusion. Does Acryform increase or decrease the light and heat factors?The textured surface Acryform enhances the refractory ability of the base material. The natural UV stabilizers in the substrate of Acryform diminish heat transmission. Return to the top of the page. Return to the top of the page