Cutting High Pressure Laminate - Abet Laminati

[tDot]

I'm in talks with a local construction company to produce all of their exterior panels for several residential high rises.  They currently have all panels shipped 1/2 way across the country to their other branch to be milled on a CNC.  I've shown them what I can do with the Festool system and they are extremely impressed.  The first product that I would mill for them is Abet Laminati, it is a 10mm thick High Pressure Laminate, made from kraft paper and phenolic resin, it's very heavy and dense, a sheet is around 125lbs.

I have a couple questions. 

What blade would you guys recommend. I currently have the Aluminum cutting blade and all the wood blades for my TS75. I've made all the sample cuts with the aluminum blade, as it has a triple chip grind, similar to the Laminate blades, and it's preformed well, but I'm curious if the Laminate blade would work better.  Thoughts?  How long should I expect these blades to last?  I will have 450 sheets to break down into 775 panels, making approximately 7500 lineal feet of cuts.  I dont have any experience with Tenyru, but would their Laminate blades be better?

Would there be any benefit to buying a TS55 for this project, other then just weight?

What type of router bits would you recommend for milling interior cutouts (lights, switches, etc)?  It needs to have a very tight radius corner.  I was thinking about 6mm diameter max.

The sheets are 51" x 120", I was planning on building a supersized MFT, with two rails and two squaring fences, for either rip or cross cuts.  Any other ideas?

Thanks for any ideas or insight you guys can offer.

 

[Tim Morris]

I am not familiar with the aluminum blade for the TS but I have done a few feet of laminate fabrication. Triple chip grind is the only way to go for chip free cuts in laminate or anything plastic laminated. On the saw I would think the 75 would serve better as it will not work as hard, larger motor, as the 55. I don't own the 75 but I often get mine warm if I have a large run of straight line ripping of material and have wondered if the 75 would help decrease this problem. As far as Tenyru I have only used thier aluminum blades in SCMS with very good results as far as quality of cut and durability. Lastly I would try a 1/4" carbide spiral downcut for your cutouts.

 

[Dan Clark]

tDot,

Regarding the saw, if you already have a TS75, I don't see any benefit in getting a TS55. 

Regarding rails, if you're cutting that many sheets, production speed will be critical.    Although expensive, I think it would be worth the cost to get the 5000mm rail: http://www.festoolusa.com/products/guide-rails/197-guide-rail-fs-5000-491500.html.  I have a 3000mm and like it MUCH better than joining two shorter rails. 

Regards,

Dan.

 

[score0matic]

several quick questions.

how many are you looking at fabricating in the next year?

Will these be fabed on site or in your shop?

are the finished sizes consistent?

do your cuts need to be ripped first, if so how often.  The long rails are $$$$$ so this is an important ?

I think the aluminum blade or maybe the laminate blade will be fine....... Depending on question 1 you will need to purchase extra baldes and get to know your saw shop better as this product is hard on blades.

if you will be onsite  and you need to rip first  i suggest a 3000, 1040,  in addition to the one that came with your TS75.  The issues of moving the 5000 to and from a work site are huge.  If it is in your shop then a 5000 is high up on the Cool Factor.

If you are working in your shop.  Do you have the room to handle these panels.  how are they off loaded from the shipper? i would look at making a moble tilting cutting table.  check out a local small glass shop for ideas there.

On site if you will be doing a lot of them you may consider building a knock down cutting table.

Craig

Craig

 

[tDot]

Thanks for your thoughts.

I will probably have to rip some of the sheets first, but I'm still waiting for a material take-off so that I can plan a full cut list, then I'll know the order of my cuts.  But I'm assuming that I'll have to buy the 5000mm rail, and then I'll likely cut it down to 3700mm or so.

90% of the panels will be fabed in my shop and about the same number will be one of two sizes (approx. 310mm x 620mm or 620mm x 620mm). The custom panels may be cut in my shop or on-site, that is unclear at this time.

I think that I'll have atleast two and maybe three blades in rotation, so that I can have two in the shop and one being sharpened.

 

[score0matic]

in that case i would look at a mobile cutting table  in the range of 60" x 132"    make a base on casters and the table to tilt almost vertical for loading and itlt back for cutting.  set up a cross cut  jig  Ala Steve Jones style  http://festoolownersgroup.com/festool-jigs-tool-enhancements/cutting-table/ and maybe even add in my rip guides

pm me and we can talk

Craig