Advanced Technology ClearCore - Manual

ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05
Page 1
Clearcore
tm
Fabrication Manual
Introduction
. What is Clearcore
tm
? A clear thermoplastic (usually Acrylic based
although Polycarbonate, PETG, and others can be used) with decorative colors and
patterns reverse laminated (second surface lamination). The decorative surface is seen
though the clear portion of the laminate. Unlike other similar products on the market
Clearcore
tm
is suitable for both Interior and Exterior application. It can be laminated
similar to HPL’s or formed similar to acrylics.
Fabrication
Clearcore
tm
fabricates similar to acrylic sheet and is laminated to substrates similar to
High Pressure Laminates.
Sawing, Routing, and Drilling
Saw blades- OK- suitable for cutting acrylic. 80 tooth, 10” diameter is common. Typical
rake is 5-10 degrees and teeth clearance angle is 10-15 degrees.
Typical saw speeds:
6 inch Dia. 6400 RPM
8 inch Dia.
5000 RPM
10 inch Dia. 4000 RPM
12 inch Dia
3000 RPM
Band Saws- OK- use a blade suitable for cutting acrylic.
All cut angles should be radius’d to prevent stress cracking. 1/8” is suitable.
Routers- OK- use bits suitable for cutting acrylic.
Drilling- OK- use twist drills with angle 60-90 degrees. These prevent chipping and
cracking.
Speeds of approximately 3500 RPM are suggested.
NOTE: All Clearcore
tm
products must be sawed with the backing side facing up
(acrylic side down) this is to insure a cleaner cut and that no damage is done to the
decorative backer foil.
Forming
It is important the sheets be slowly and evenly heated throughout. Sheets with non-
uniform temperatures can pull unevenly.
Cold bending. .060 can be bent to a radius of 4 inches.
.120 can be bent to a radius of 18 inches.
Hot bending. Down to ½ inch with proper equipment.
Heating
275-320 degrees is recommended. Continuous clamping is recommended.
This will vary with the type of heating and depth of forming needed.
Slow heating to eliminate stress is desired. For example it should take about 3 minutes to
bring .125 thick sheets to forming temperature of 300 degrees F. Slow cooling after