3D Laminating Glossary

3D Laminate: Also known as rigid thermoformable foils (RTF) or thermofoil, 3D Laminates (3DL) are designed to soften under heat, then form over and bond to a 3D shaped substrate using the process of 3D Laminating. 3D Laminates give designers the option of forming a single layer of laminate over contoured surfaces and profiled edges in one step, creating a product that is seamless down to the bottom edge. 3D Laminates are available in a variety of solid colors, printed wood grains, and various abstract designs.

3D Laminating: The lamination of three dimensional pre-shaped panels with a thermoformable laminate using a controlled sequence of heat and vacuum, heat and positive pressure, or a combination of heat, vacuum and positive pressure. The process can be accomplished in positive pressure membrane or membraneless presses, as well as membrane or membraneless vacuum forming systems.

Bladder: See membrane.

Bladder Press: Although this term is often used to describe a membrane press, it is our belief it was originally used for liquid filled membrane presses developed in the late 1960’s and still used today. In this system the membrane is either pressurized via the injection of thermal oil or, in the case of liquid bed presses, through displacement pressure as the press is closed. The thermal oil is heated to provide the heat source. Since liquid pressure is safer to operate than air pressure, much higher pressure capacities are available with this technology.

Diaphragm: See membrane.

Dog Ears: Sometimes referred to as corner pinches or corner folds where the 3DL folds together and forms an imperfection on the corner of a part.

HVLP System: High Volume Low Pressure (HVLP) systems are characterized by a spray gun requiring low fluid pressure (LP) but a high volume (HV) of air to atomize the adhesive. Compared to conventional spray systems, overspray is reduced resulting in less adhesive consumption and lower filtration needs. Dual regulators are needed to reduce conventional shop pressure down to required levels for both fluid and atomization pressure.

MDF: Medium Density Fiberboard. Double refined or “door grade” MDF is recommended for 3DL applications.

Melamine Back: Thermally fused melamine. (TFM)

Membrane: Sometimes referred to as a diaphragm or bladder, membranes are made from advanced, high strength silicone or natural rubber sheet material. The material must be capable of stretching over a 3D shaped substrate under vacuum and/or pressure, then return to its original state without taking on the shape or imprint of the previous part being laminated. It also must be capable of holding very high pressures of up to 120 psi (8 bar) in an enclosed chamber.

Membrane Press: Usually refers to a press that incorporates the use of a membrane as well as positive pressure and vacuum. However, some membrane presses eliminate the use of vacuum below the 3DL and merely allow a way of escape for trapped air as pressure is applied. The membrane draws heat from the heating source, usually a platen, then transfers that heat into the 3DL for softening, forming, and adhesive activation. Air pressures of 30 PSI to 60 PSI are typically used for 3D Laminates.

Membraneless Press: Usually refers to a press that incorporates the use of positive pressure and vacuum but without the use of membranes. In this system a full sheet of 3DL must be used to create a pressure chamber above the laminate and a vacuum chamber below. In some cases presses have been designed to eliminate the vacuum system below the 3DL and merely allow a way of escape for trapped air as pressure is applied. The 3DL draws heat directly from the heat source, usually a platen, and then forms over the substrate and activates the adhesive. Air pressures of 30 PSI to 60 PSI are typically used for 3D Laminates.

One Part Adhesive: Typically refers to a waterborne polyurethane dispersion (PUD) that is pre-catalyzed by the manufacturer and does not require mixing prior to application. It is typically applied manually using an HVLP spray system but can be applied using a robotic spraying system as well.

Pedestal: Sometimes referred to as riser boards, jigs or blocks, pedestals are used to lift the part being laminated up off of table to allow the 3DL to stretch down around all edges and tuck slightly under the part so that it is completely sealed to the bottom edge when trimmed.

Pin System: Pin systems are designed to eliminate the need for custom pedestals for every size part. Pin systems can be manual, semi-automatic, and fully automatic.

Pin System – Closed: Closed pin systems are characterized by pins that are so close together they function as a solid pedestal.

Pin System – Open: Open pin systems are characterized by pins that have large gaps in between them.

Pre-applied Adhesive: This is a hot-melt adhesive system that is applied to the 3DL in order to eliminate the process of applying adhesive to the substrate prior to pressing. As a hot-melt, the adhesive does not have a hardener added for additional heat resistance and will soften as it approaches the activation temperature.

PUR: Polyurethane reactive adhesive (moisture cure) used in hot melt form to profile wrap 3DL for use as molding and as stile and rail material for 5-piece thermofoil doors.

Riser Board: See pedestal.

Telegraphing: A defect that has two potential causes; poor board quality, machining quality or debris telegraphs through from underneath the 3DL, or an imprint from the membrane has transferred onto the surface.

Thermally Fused Melamine: Commonly referred to as TFM, melamine saturated paper is thermally fused directly to a substrate of particleboard or MDF.

Thermoformable: A product that is capable of being softened by heat and formed over a substrate or mold using vacuum, positive air pressure, or a combination of both. The product then returns to a stable condition when cooled.

Thermofoil: See 3D Laminate.

Two Part Adhesive: Typically refers to a waterborne polyurethane dispersion (PUD) that is mixed with a hardener by the operator just prior to being applied to the substrate. The hardener works to increase the heat resistance to temperatures well above the original activation temperature. It is typically applied manually using an HVLP Spray system but can be applied using a robotic spraying system as well.

Vacuum Press: Often referred to as a vacuum former, this system eliminates the use of a pressurized chamber above the 3DL and relies only on vacuum under the 3DL to form it to the substrate. The 3DL is heated using either heating lamps or infra-red systems. Some vacuum presses offer the option of operating with a membrane for greater security and flexibility.

Wrinkles: A defect whereby the 3DL has folded together as it was being drawn or pressed down to the surface of the part.