Our Process
Membrane pressing typically uses an inflatable membrane, in combination with a vacuum, to press and bond the pre-heated decorative plastic sheet onto a shaped substrate of MDF (medium density fiberboard).
This process has been widely used throughout Europe and Asia for the last 30+ years and has rapidly gained acceptance here in the US as an exciting, greener and economic alternative to traditional decorative finishes such as high pressure laminates, paint, stain and lacquer.
Some of the advantages of this process over the traditional methods of applying durable decorative finishes are:
Almost unlimited design possibilities. The more curves and three dimensional the shape, the more successful the process.
High durability. Different grades and formulations of materials for horizontal and vertical surfaces and especially high traffic areas make for long lasting and virtually maintenance-free products.
Seamless surfaces. Membrane pressed products provide both ascetic and functional advantages over high pressure laminates by eliminating problem areas such as seams and dark joint lines.
Environmentally friendly. Membrane pressing eliminates environmental issues involved with painting and the use of solvent based products.
The Substrate
A consistent and stable material, Medium Density Fiberboard, or MDF, is manufactured from renewable sources in large, sophisticated plants (Flakeboard) in a wide range of thicknesses; we typically use ½” to 1-½”. Different formulations are available such as fire-resistant, water-resistant, formaldehyde free and lightweight. MDF Produces a surface free of defects with an even texture and an excellent bond for adhesives, and it's excellent machining qualities allowing us to produce intricate shapes to great accuracy utilizing our CNC routers.
The Adhesive
Water based, two-part polyurethane dispersion (Helmitin) is sprayed on to the machined MDF and allowed to dry. The adhesive is activated by heat as the laminate is brought into contact with the MDF. The Helmitin adhesive provides a total bond between the laminate and the MDF even if the product is exposed to high ambient temperatures, with the final product being totally sealed against ingress from moisture.
The Decorative Surface
Laminates are manufactured from various products according to the required end use, the most popular being PVC. However, the use of alternative materials, such as acrylic polymers and polyester resins, is gaining acceptance as they are more environmentally friendly. PVC films (Renolit and Omnova) are produced by the calendaring process in both solid colors and printed films for wood grains and patterned finishes. The surface finish can vary from high gloss to textured to even a soft, spongy finish.
Polyester films are gaining in popularity due to their greener footprint and are, again, available in many colors and finishes (Riken). Acrylic polymers (Kydex) are excellent products for high traffic situations and are available in custom solid colors as well a range of stock colors and wood grain finishes. These products can be produced in relatively small quantities. Many of these products meet or exceed fire safety and other regulatory requirements, and surface wear and durability can match or exceed high pressure laminates.