While Envision Plastics’ claim to fame is our No Molds Required (NMR) plastic fabrication technology for custom plastic enclosures, we also dabble with a material called ACM (Aluminum Composite Materials).
ACM fabrication is a bit different than NMR plastic fab, but it utilizes some similar equipment so we figured we may as well add it to our service offering!
So far we have utilized this material to manufacture dozens of custom ACM parts including: enclosures, panels, signage, and other parts that lend themselves to the benefits of this unique aluminum/polyethylene hybrid material.
ACM sheets can come in different thicknesses and have varying facer thickness (see picture to below). Most often, when forming is required, we use a minimum ACM thickness of .118" with facer thicknesses of .012" on each side.
The reason for this is when we CNC route the ACM, it leaves some polyethylene plus the .012" aluminum facer on one side to allow for rigidity after the forming process.
Thinner facers may crack. However thinner facers (such as .008") still have their advantages with flat panels such as used in some signage applications. A thinner facer allows for a lighter and more economical ACM product.
Advantages of ACM
Due to the many benefits ACMs have, we really feel it is a viable option for our customers on select applications. These benefits include:
• Lightweight (50% the weight of aluminum in the same gauge)
• Several colors and finishes to choose from that come standard and pre-painted
• Completed parts can be shipped in the flat to save on shipping
• Parts can be assembled at your facility or a job site since parts can be formed by hand
• Can be stored at your facility in the flat saving space
• Surface is ideal for digital printing
• Can be used indoors or outdoors
Hardware Used with ACM Fabrication:
Because of the unique nature of aluminum composite material, hardware choices must be considered more carefully. The thin aluminum facer layers will limit the typical sheet metal fastener types and the polyethylene plastic does not necessarily allow for heat staked inserts like we are used to using at Envision.
There are three main hardware types we use to mechanically assemble or fasten ACM fabricated part components for enclosures, panels, and other types of housings. These are: rivets, screws, and specific PEM blind standoffs.
Rivets:
Many different types of rivets can be used with ACM. All that is required are two through holes that line up and the proper diameter and length rivet for the application.
If need be, the hole can be countersunk to accept a flush head rivet.
Screws:
Any type of self-tapping screw can be used with ACM. The threads of the screw will bite mostly into the polyethylene core of the material versus the thin .012 or .008 layer of aluminum facer.
Blind Standoffs:
• CSOS (i.e. CSOS-632-4): Intended for thicker ACM sheet (at least .093), which allows the blind mounting hole (milled recess area) to be deeper at .075
• CSS (i.e. CSS-632-8): Intended for thinner sheet (at least .062), which allows the blind mounting hole to be shallower at .043 deep.
Brands of ACM Used (So far):
There are many types of ACM brands on the market. The three brands most used at Envision are Dibond, Alupanel, and Signabond. Specific material data sheets can be found on our ACM materials page for this information.
If you would like to learn more about ACM fabrication at Envision Plastics and Design, please do not hesitate to visit our website page outlining our capabilities here:
https://envplastics.com/services/acm-fabrication
