ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05
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 nonuniform 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
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ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05
forming is necessary to prevent stress. Parts not cooled properly may have a tendency to
warp. Bubbles or blisters are a sign of excessive heat, moisture in the sheet, or Uneven
heating. Bumps are caused by air trapped between the form and the material.
Edge Polishing
It is possible to polish out the edges with the same techniques used to fabricate acrylic.
Flame polishing, however, is not recommended. Rounding of corners or smoothing out
irregular cuts can be done with medium metal files. Edges should be well machined
sanded or hand scraped using a stationary polishing head 8-14 inch in diameter wheel
with 2-3 inch width of muslin. 1st buff using a medium coarse buffing compound, then
use rouge as a finishing compound. Products such as 3M Finesse it tm and Novus plastic
polish are suitable.
Surface Polishing
It is possible to remove scratching from the surface using the same methods used for
acrylic fabrication. 1st use the same technique mentioned for edge polishing. If the
scratches are too deep for that type then you can use water with fine grit sandpaper (240320 grit) and then use 400 grit as a 2nd step and then use 500 grit as a final step. You need
plenty of water for this procedure. Products such as 3M Finesse it tm and Novus plastic
polish are suitable, follow products application recommendations.
Laminating
It is possible to laminate Clear Core tm to typical substrates used for High Pressure
Laminates. Gypsum board, paperboards, and concrete are NOT recommended.
Typically MDF, Particleboard, Plywood, Hardboard are suitable materials. Clear Core tm
has been tested using DAP / Weldwood non flammable (Neoprene Rubber Formula) with
good results. Neither flammable solvent, nor gel based contact cements are
recommended, and should be considered only after the customer has done sufficient
testing to assure suitability to their application. Extra care must be taken to insure that all
solvents or water have been dried according to manufacturer’s recommendations prior to
joining. Spraying produces the best glue line and is recommended. Cold Press adhesives
suitable for high-pressure laminates can also be used. Counter balancing of the core
material similar to high-pressure laminates (HPL’s) is necessary to prevent warping of
the laminated sheet. Use the same methods and counterbalance material used with HPL’s
for good results. For optimal results, counter balance with the same thickness acrylic
sheet as Clearcore tm.
Important Notice. Many items have protective film on the BOTTOM and TOP of the
sheet to protect against scratching during handling and shipping.
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ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05
1st time users should request a sample piece (approx. 1 x 2-ft.) to check their fabrication
and lamination techniques.
The BOTTOM FILM MUST BE REMOVED prior to applying adhesive.
TOP FILM is to remain in place during fabrication to prevent against scratching during
the fabrication process. However it is extremely import to visually inspect the sheet prior
to fabrication to insure that there are no visible defects that can’t be accepted. In the
event that inspection can not be adequately inspected with the top mask on the customer
must remove the mask prior to fabrication to inspect the sheet. Then the customer must
re-mask the sheet with another mask prior to starting fabrication.
Storage
Before any fabrication, sheets must be conditioned for a minimum of 48 hours in the
same room as the substrates. 70F and relative humidity of 50% is recommended.
Masking should be left in place on both surfaces (if applicable) until fabrication.
Sheets should be stored horizontally completed supported or vertically at a slight angle in
an A frame type rack.
Insure that the sheets are not stored near heat sources that can deform the sheets.
Care and cleaning
Use only Naphtha or Mineral spirits to remove excess adhesive. Avoid using Acetone,
MEK’s, etc. as these may damage the surface.
Use a mild soap solution that does not contain alcohol or ammonia. Use a soft lint free
cloth to dry.
DO NOT use any abrasive cleaners as these will dull and scratch the surface.
Characteristics
Our (optional) 1/8 acrylic performs like standard acrylic. Our High Performance
modified acrylic (standard) .060 thickness (designated by HP in the part #), is rigid and
tough, lightweight and offers ease of fabrication and machining. Cutting, routing, and
cementing can be performed. Clearcore tm offers the look of acrylic with extra impact
strength to aid in fabrication, shipping, handling, and prevent edge chipping.
All sheets come with a removable polyethylene mask to protect the sheet during
handling, shipping and fabrication. Most are suitable for interior or exterior applications.
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ATI-Clearcore Fabrication Manual Revision 0 Effective Date: 11/16/05
Dimensional Stability.
Sheets will experience an expansion or contraction when exposed to a temperature or
humidity change. Shrinkage will occur when the unclamped sheet is subjected to
forming temperatures, but post-forming stability is excellent.
Flammability
Our sheets are combustible thermoplastic. Precautions should be taken to protect this
material from flames and high heat sources. Rapid burning to completion occurs if not
extinguished. The products of combustion, if sufficient air is present, are carbon dioxide
and water. However, in many fires sufficient air is not present and toxic carbon
monoxide will be formed.
Uses:
Many interior design applications, where decorative HP laminates could be used (Not
recommended for high wear horizontal surfaces). Furniture, Store fixtures, displays,
exhibits, and signage are a few other uses. For exterior application, Clearcore tm can be
used for automotive interiors and exteriors, boat dashboards, outdoor signage and much
more.
Important Disclaimer and Warranty: The information and statements contained herein are not to be
taken as a warranty or representation for which we assume any legal responsibility. The information is offered
solely for your consideration, investigation and review. Users must perform their own test to insure the
products are applicable and suitable for any particular purpose.
The Seller warrants that the products sold hereunder shall be of merchantable quality and shall conform to the
specification herein. However, the buyer assumes all risks. The only remedy to the buyer shall be for the seller
at its sole option to either replace the sheets which are deemed to be defective or refund the purchase price. The
seller makes no warranty; express or implied based on the fitness of the product for any purpose other than
stated herein. The seller shall not be liable for any additional loss whatsoever, including a claim for breach of
merchantability, any incidental, or collateral damage or loss, It is the buyer’s responsibility to inspect the
product upon receipt and prior to any fabrication. Any claim whatsoever shall be deemed waived once any
fabrication or cutting is started. Any claim shall also be deemed waived unless presented in writing within ten
days of receipt of said product. It is the sole responsibility of the purchaser to do the necessary tests to insure
that these products meet the purchaser’s requirements. NO WARRANTY IMPLIED OR OTHERWISE
SHALL APLY to products that undergo manufacturing.
Revised January 22, 2004
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