Málama Composites

AinaCore^® bio-foam panels can be cut, fastened, glued, surfaced and finished using a number of traditional manufacturing techniques. These light-weight structural panels have consistent cell structure and uniform density, and they machine professionally. Of course, always follow proper safety procedures to avoid injury.

Cutting

Radial saws, band saws and rip saws effectively cut AinaCore^® panel products. Eye protection, dust masks and a dust collection system is advised. Hot wire cutting, often used to machine EPS (expanded polystyrene foams), is not recommended.

Shaping:

AinaCore^® is an ideal core material for shaping complex three-dimensional forms. Standard hand tools (shapers, planers and sanders) are effective. The consistent density of AinaCore^® also lends itself to CNC (computer numerically controlled) routing and shaping.

Fastening:

Composite construction often employs insert fasteners, which can be potted using epoxy or other thermoset resin systems. Alternatively, manufacturers can inset wooden or plastic hard points and then fasten into these surfaces.

For low stress applications, wide flange screws can be used. It is not advisable to nail into foam cores as they lack the pull strength of solid wood lumber, plywood, particleboard or MDF.

Gluing:

AinaCore^® is a polyurethane material. As a result PUR glues work well, as do two-part epoxy systems and hot melt glues. Gluing composite structures is often an excellent fastening solution as it spreads the loads across much larger surface areas.

Surfacing:

AinaCore^® panel products can be successfully surfaced with high pressure laminates, wood veneers, and other materials, using standard adhesives. We do not recommend thin paper or melamine surfaces, particularly in horizontal applications, as the impact strength of our foam cores is not as robust as that of solid panel products.

AinaCore^® can be edge-banded using traditional machinery. However, high pressure laminates or lumber banding is advisable rather than using thin plastic edging or t-molding. You may have to lower the pressure on the pinch rollers of the edge-bander to avoid denting the core material.

AinaCore^® is an ideal core material when combined with woven or non-woven fiberglass cloth and finished with appropriate resin systems. This type of fabrication can be accomplished in hand lay-up, vacuum bagging, resin transfer molding or other composite fabrication methods.

We also encourage you to explore natural fiber cloths and bio-based epoxy resin systems in the development of more sustainable products.

AinaCore^® can be painted with various water-based and solvent based paints. Surfaces should be blown clean of any foam dust before painting. The material will absorb paints, and thicker solutions are advised.

Curving:

AinaCore^® can also be used to create structural curves. Panels can be bent over radius forms, then laminated with HPL or veneer skins.