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How to make your own composite board
The following step by step tutorial has been submitted by:-
The manufacturers would rather you didn’t know this, but producing your own composite (Dibond type) material is an amazingly simple process which I will now reveal in this simple step by step tutorial:-
Making your own aluminium composite material makes good business sense and will save you a fortune in your materials cost.
One of the main ingredients used in the method I will be describing are old PVC foamboards (Foamalux, Forex, Foamex et. al).
And remember, by re-cycling old Foamboard materials and off cuts you will be helping to save the planet (as well as giving your company green credential "bragging" rights).
Overview
Here is a diagram showing the make up of a typical composite material. It consists of a polyethylene core sandwiched between aluminium faces
The Polyethylene core is a plastic which is readily available by converting old PVC foamboards (Polyvinylchloride) into polyethylene (all the other ingredients used in this step by step are readily available in most households)
First the chemistry:-
Polyvinylchloride is a long chain polymer plastic material made from Carbon, hydrogen and Chlorine atoms
Whereas Polyethylene is virtualy identical containing atoms of Hydrogen in place of chlorine
Step 1
First we must devise a method for converting our old foamboard material (PVC) into polyethylene (PE) by removing the chlorine atoms and replacing these with Hydrogen atoms.Here’s how it’s done:-
Use a blender to chop up the old PVC signboard material (If you don’t have one of your own – borrow your mums).
The powdery material this produces is then converted into polyethylene (PE) by simply adding vinegar (a mild acid and therefore a ready source of H+ ions) and charcoal (the charcoal acts as a catalyst turning the PVC into black Polyethylene).
Place the mixture in a bucket and allow to stand for a few days while the chemical reaction takes place.
Be sure to store the mixture in a well ventilated area as the chlorine gas that is given off by the chemical reaction is poisonous in high concentrations.
Step 2
Now that we have converted our PVC source material into Polyethylene, we can begin the process of making up our composite boardsFirst we must add a resin material to our prepared PE mixture. This will act as a binding agent once the resin has set.
Now we add Baco foil (other brands are available) to provide the face material of our composite
The tin foil is spread out on the workbench and the resin impregnated PE mixture is poured on top, then rolled out to a 3mm thickness using a rolling pin (If you don’t have a rolling pin – and can’t borrow your mum’s – then a discarded vinyl core tube will probably suffice)
Step 3
Finally another layer of tin foil is placed on top and the entire laminate is trimmed to size using a sharp blade.Once set and hardened, the face is coloured by flood coating the sheet using ordinary vinyl readily available in any sign shop.
Pictured below – an example of composite board made recently using the process just described:-
I hope you find this tutorial to be of use to you in your business 😮
Next week I will be revealing the secret of how to make your own Foamex sheets using only shaving foam and fibreglass resin 😕
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23 Replies
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Love it Phil, will be trying this next week for sure.
I do think that shaving foam will be to sturdy for foamex though 😀 -
Ah yes very good Phil, first one the year, I am now away for a long stand and a tin of tartan paint.
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I make mine with chewing gum and yoghurt pot lids
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how do u keep it so even ? 😉
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I put mine under the mattress overnight to set. Certainly no chance of any movement there
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Don’t forget the Spur Lash Graham :lol1: :lol1:
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Phil’s next blog:
How the make a Premium cast warping media using household cling film and some food colouring 🙂 -
Most of the vinyl on ebay is cling film!
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quote Ian Johnston:Phil’s next blog:
How the make a Premium cast warping media using household cling film and some food colouring 🙂Hope not Ian, I want to know how I can make foam board from a tin of shaving foam & I’m hoping you can use any shaving foam as that Gillette stuff is a bit expensive :lol1: :lol1:
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I forgot to mention.. if you’re planning to make folded pans out of the composite material you’re making, then be sure to use Bacofoil professional which is a bit thicker than the standard product 😮
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will this be in your new book?
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Looking for a cheaper alternative so will this work 😀
http://www.mysupermarket.co.uk/asda-com … x_30m.html
Kev
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This works, just tried it
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Very clever phill. :lol1:
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Phil! you have way to much time on you’re hand’s…
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I should point out that this thread was originally timed to go out on 1st April 😉
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quote Phill Fenton:I should point out that this thread was originally timed to go out on 1st April 😉
ohhh… likely story!
is this your way of getting round the warranty of "your" product phill?
good try, but i have just checked and you are clearly 3 hours short of the 1st of April.
Think you have some explaining…. (hmm) -
I was undertaking a "book signing" tour in the Transnistria region of the Republic of Moldova at the time when I posted this. The republic of Moldova (as every knows) is three hours ahead of us. 🙄 ..sniff
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I can’t get the lid of the vinegar bottle and I need these sheets for tomorrow.
Any tips? 🙁 -
You could try using donkey urine (which is also quite acidic and a ready source of H+ ions) 😮
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Won’t help you this time round Harry but if you post the offending vinegar bottle to yourself using Royal Mail when it comes back you will find the lid is half off allowing easy removal. If you wrap the bottle in kitchen towel before posting this will absorb most of the vinegar that has leaked from the bottle & can be wrung out into your next batch of mixture.
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quote Phill Fenton:You could try using donkey urine (which is also quite acidic and a ready source of H+ ions) 😮
I need that for the cabbages. 🙄
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quote Martin:Won’t help you this time round Harry but if you post the offending vinegar bottle to yourself using Royal Mail when it comes back you will find the lid is half off allowing easy removal. If you wrap the bottle in kitchen towel before posting this will absorb most of the vinegar that has leaked from the bottle & can be wrung out into your next batch of mixture.
Royal Mail? Is that what the Queen does, deliver mail? We use the Post Office. 😀
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