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ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05

Page 1

Clearcoretm 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

1 2 3 4

Shrnutí obsahu

Strany 1 - Forming

ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05 Page 1 Clearcoretm Fabrication Manual Introduction. What is Clearcore tm? A

Strany 2

ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05 Page 2 forming is necessary to prevent stress. Parts not cooled properly may h

Strany 3

ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05 Page 3 1st time users should request a sample piece (approx. 1 x 2-ft.) to chec

Strany 4 - Uses:

ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05 Page 4 Dimensional Stability. Sheets will experience an expansion or contracti

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