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Design Life blog

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Design   |   Life   |   Marketing   |   Production |  Tips & Tricks

Did your 3DL color get discontinued?

11/17/2020

1 Comment

 
Peelstix Color Palette
by Matt Arriola

Does it drive you crazy when you go to order a thermofoil color from a vendor only to find out it has been discontinued and now requires a large custom order? Often these custom orders can be 3,000 or even 5,000 meters. 
Although we cannot guarantee to not discontinue an item, Dackor is the leading company on maintaining stock.

But aside from our 250 plus stock items that we maintain for our clients, Dackor has a great custom program to enable you to switch more and more colors over to our company.

You can go to www.Dackor.com/colors and look for a very close or close match first or contact your Account Managers at 407-654-5013 to do the searching for you. In addition you can visit https://www.dackor.com/custom and input your image right on our site.

What if you need to color match?
STEP 1: INQUIRE >  Fill out this form and we will let you know within 2 business days or less if we are capable of your required match quality.  Please note that if we have the tooling our MOQ is 600 linear yards for melamine matches (in distribution) or leathers or 1200 yards for all others. 
  • FORM FOR COLOR MATCH
Please allow 2 business days for us to evaluate target.

STEP 2: MATCH?   Within 2 business days we will confirm match capabilities. You can then issue a PO for $500 color match deposit which is fully credited upon order. Matches take 4 to 6 weeks and you will receive a lab sample.


STEP 3: EVALUATE !    After you receive the match and approve simply issue a PO for the agreed quantity and await 10 to 12 weeks for the material to be available , FOB, Orlando. This can be expedited 4 to 6 weeks by air for an additional fee.  We will typically produce 2,000 to 3,000 yards at our discretion for back up inventory. After the initial PO and MOQ you may order from remaining stock as needed.
Color match request form
Inquire> | Match? | Evaluate!

Examples of Recently discontinued 3D Laminate colors in the marketplace.
Ebony Ash, Light Maple, Black Haircell, Antique Whitewash, Russian Maple, Soprano, Sugarloaf Maple, Matte Black, Matte Malachite, Matte White, Oxidized Pewter, Platino Granite Sand, Platino Granite Tanin, Pompeii Marble Espresso, Pompeii Marble Gray, Rift Oak Brown, Rift Oak Gray, Carbon Fibers Silver, Fibers Concrete, Cashmere, Fusion Maple, Imperial Smoke, Rift Oak Natural, Slate Gray, Smokehouse Oak, Stratus White, Tin Ceiling and Venus Silver.



1 Comment

Refacing your Kitchen

11/14/2020

1 Comment

 
When refacing your residential kitchen there are various options when utilizing Dackor materials. The first question is if you are looking to change the layout drastically. In most cases where you want to significantly replace the layout of the Kitchen you will go with new cabinetry. If, however, you are OK with the layout refacing can save you thousands. Once you have decided to reface there are various other decisions to make. Some decisions are:

-Should I replace the countertop?
-What style doors do I want? Slab, Shaker or Raised Panel
-Do I want soft close hinges on the doors? We recommend as its a small expense

If you are replacing your countertop, generally you want the countertops to be replaced before refacing so damage will be done do the doors or boxes. The most popular options for countertops are quartz and natural granite however some may also choose laminate countertops.

Once you have your countertops installed and the color chosen it is more easy to choose colors for the doors. 

How does cabinet refacing work using Dackor materials? Dackor recommends a professional refacer who has experience working with Dackor Peelstix for the cabinet boxes and someone who has lots of experience hanging the doors. 

How does the refacer do the job? 
The refacer will measure your doors to the nearest 1/8" and take notice of the type hardware they need to get, any unique aspects of the job such as the box condition and any unique installation challenges. After they take the measurements they usually get a deposit so that they can custom order the doors to match your specific Kitchen. Typically it can take 2 to 3 weeks to receive the doors in however sometimes it may be faster. 

When the installer comes to install the job, it typically takes them 2 to 3 day. They take off the old doors, clean and prepare the box to be refaced using Dackor Peelstix. They then install the new doors and you get a completely transformed Kitchen saving thousands and with the color of your choice.

The benefits of refacing in most cases are:
-Saves money on a dumpster
-No need for an electrician or plumber
-No need for tear out and therefore no drywall damage or tile damage
-Brand new doors and completely refaced box on the external of the cabinets
-Quick install with no dust or debris
-Ability to use your kitchen in the evenings even during the install process

Imagine having a brand new looking Kitchen, not throwing away perfectly good boxes and not having to deal with numerous trades all of which cost more and create more complications.

Although many jobs can have complications, you can rest easy knowing that you are using a quality product that will create more value in your home and put a smile on your face when you see the final results!
1 Comment

Dackor 0.15mm / 6 mil and 0.2mm / 8mil

10/22/2020

0 Comments

 
This article is to explain more about the different thicknesses we produce and for what application they are good for.

THICKNESS REFERENCE:
0.15mm = 6 mil , semi rigid
0.2mm = 8 mil, this thickness and above are rigid
0.25mm= 10 mil
0.3mm= 12 mil
0.4mm= 16 mil
0.45mm=18 mil
0.5mm= 20 mil
0.7mm=28mil

MEMBRANE PRESSING / VACUUM PRESSING: For Solids and Woodgrains,  Dackor's 12 mil is most common as it can be membrane pressed by all however some company's even have the expertise to profile wrap as well. When you press, it uses heat and suction to form over the mdf components. This means that the material is pressed into the substrate. By going thicker you are able to hide more imperfections. In addition, by going thicker, deeper embosses can be incorporated for more realistic surfaces. Quality producers know that Dackor has a plethora of thicker materials as well and we do this to enable our customers to have higher quality parts and also to create more realistic woodgrain textures.

PROFILE WRAPPING: When profile wrapping, companies do not experience suction of the material into the mdf so thinner products can be used. The most common sizes are 6 mil and 8 mil. When we produce 6mil we do so with a semi rigid vinyl. This reduces cost but also enables the product to wrap well. Some companies love semi rigid due to its ease of wrapping however semi rigids often are not as strong or durable to scratches and wear. For that reason we offer rigid 8 mil product to enable the material to be thin enough to wrap yet more durable to scratch and more rigid to process. 

SEMI RIGID VERSUS RIGID: The best way to describe the difference is that semi rigid feels more like a thin shower curtain that is more flimsy in your hand. This is caused by adding more plasticizers to enable the product to stretch. This also lowers the cost of the product. Rigid, however, uses a very low amount of plasticizers and enables the product to be more rigid. The product still goes on a roll however its really more like a thinner version of membrane press laminate.

FLAT LAMINATION: Companies can flat laminate 12 mil and thicker vinyls however this is typically done with a PUR line or 2 part epoxy. For most flat lamination lines you would utilize a 6 mil or 8 mil. This is personal preference. It should be noted the strengths and weaknesses are that the 6 mil applies more quick and cost less however being thinner it may show more imperfections in the substrate whereas the 8 mil is more rigid. Please note that the heat utilized in processing will be different as well based upon the formulation of rigid versus semi rigid as well as the thickness. If the product is more thick it may take more heat to absorb into the material.  

MITER FOLDING: When folding the vinyl becomes a hinge. This means that you are routering a v groove in the back of the part and only kissing the vinyl. When you fold the part you get a crisp edge. One advantage of a rigid vinyl is that when you fold it thermosets better and is less likely to pucker on the edge. So there are some strengths to miter folding a rigid over a semi rigid. 

CONCLUSION: Please note that there are so many variables in lamination. There is time, heat, duration, pressure, glue used, board, humidity , user and more. This means that like all professional laminations you really need to test produce product to be sure of the thickness and formulation to be sure more ease of processing.
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How much does 3D Laminate weigh per meter / yard

10/20/2020

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Although material can weight +/- 10% the below is a rough estimate on how much 3D Laminate weighs per linear meter versus linear yard by thickness when 1420 to 1450mm wide. It is calculate in pounds per linear meter LM or linear yard LY.

Thickness-mil:  LM / LY
0.25mm-10mil:  0.98 / 0.89
0.3mm- 12 mil: 1.24 / 1.13
0.4- 16 mil: 1.64 / 1.49
0.4 w/peelcoat: 1.86 / 1.70
0.17 -18 mil: 1.7 /1.55
0.5 / 20 mil: 2.05 / 1.87

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Peelstix, Natura Stone and Accent Planks refacing

10/7/2020

3 Comments

 
A couple years ago we told you about how Dackor manufactures a product called Peelstix.
 
Peelstix is a flexible laminate that can be trimmed with knives and can be fabricated in a shop or on site with no dust or smells. By having the adhesive already on the product it can also save time. White is a very popular color and these are just a few of what we offer that are doing very well: Solid Frosty White 12, Smooth Satin White, Solid Designer White, Solid Bright White, Saffron Mahogany, Leather Brown, Summer Breeze, Egg Shell Black Claw, Ravenwood, Solid Cashmere Black, Wilsonart Fusion Maple and  Carbon Fibers. 

Well Peelstix has really taken off and is a favorite of Multifamily Housing, Refacers, Universities, Hospitals and More.

So, what has been getting refaced you might ask?
Multifamily Housing has really embraced Peelstix to update Kitchen Cabinets and Cabinet Doors along with the face frames to give the new apartment resident that updated look. Moreover, the bathroom vanities have gotten facelifts too! 

Our Accent Planks and Natura Stone are a favorite of Multifamily Housing as well. Account Planks, also a peel and stick product ideal for wall decoration. These planks decorate Accent Walls for an upscale look. Our Hand Painted Frosty White maintains a traditional woodgrain look with a beautiful Matte White Finish.
​
The Rome Marble White, which could compete with the Greek marbles needs to be physically seen and not just from a computer monitor. Not to mention it is one of our Rhino Hz extra durable grades available.

Natura Stone, the natural stack stone veneer is also a peel and stick.
Yes, it’s real stone cut to a 1/16" to 1/8" thickness variance to give a stacked stone look. It comes in 4 beautiful colors of Copper, Sapphire, Emerald and Sesame. With minimal prep it will sophisticate any space by adding dimension and texture. This stone is great for accent walls, backsplashes, or any interior vertical application.


Colors above also know as other industry names you may have heard are:
Ebony Ash, Light Maple, Black Haircell, Antique Whitewash, Russian Maple, Soprano, Sugarloaf Maple, Matte Black, Matte Malachite, Matte White, Oxidized Pewter, Platino Granite Sand, Platino Granite Tanin, Pompeii Marble Espresso, Pompeii Marble Gray, Rift Oak Brown, Rift Oak Gray, Carbon Fibers Silver, Fibers Concrete, Cashmere, Fusion Maple, Imperial Smoke, Rift Oak Natural, Slate Gray, Smokehouse Oak, Stratus White, Tin Ceiling and Venus Silver.
3 Comments

Recycling PVC

5/11/2020

0 Comments

 
Many cabinet door and component producers have asked where they may recycle PVC. As long as your product does not have glue you can visit: scrappvc.com 

Officers
Richard Silberfeld, President
Ray Brown, VP Sales

Corp. Office Address
97 Sawtooth Cove
Port Jefferson, NY 11777

Warehouse Address
1510 5th Industrial Court
Bay Shore, NY 11706

Telephone
Office: 631-969-1050
Fax: 631-969-1051
Alt. Office: 516-356-5120
Alt. Fax: 631-331-1885

Web Address
www.universalcomposites.com
www.scrappvc.com

E-mail Address
contact@universalcomposites.com

Ideal for thermofoil / membrane press vinyls.
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Vac-u-clamp

5/8/2020

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Recently there have been more cabinet companies buying vac-u-clamp machines for the use of making cabinet doors and drawers. 

Previously in older models such as the 700 series and earlier there were issues not allowing many thermofoil laminates to work on the machine however this has been solved with the newer generation of 800 and 900 series. Dackor has worked closely with customers to improve on the pressing utilizing our 3D forming laminates.

To locate Vacuclamp directly visit vac-u-clamp.com and if you buy a machine contact us directly for free pressable samples and browse this blog for pressing assistance and tips.

Also, dackor has available for sale the URL vacuumpress.com and membranepress.com should any companies be interested in purchasing these sites.

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Technical Support / Error Analysis

4/27/2020

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See the pdf version
​ 

Possible Pressing Errors and Correction Measures
 
General Measures
The film to be processed should be tempered and adjusted to the room temperature.  This means that the film should never be stored on the (especially in winter), but should rather be stored in a temperate room at 18 C for 24 hours to acclimate and warm up.  This also applies to timber material (MDF) and adhesives.
Strong temperature decline around the press, i.e. due to draught or open doors/gates near the press, can lead to the temperature fluctuations in the pressing room and adversely affect the pressing result as well as the processing quality.
Therefore, when pressing, observe the room climate with regards to temperature and humidity should be kept as constant as possible (approx.. 68F-72 F at approximately 50% relative humidity is ideal).
 
Press Layouts

Malfunctions or erroneous presses can sometimes be caused by disadvantageous component layouts on the press tray with too many different measurements (see sketch 1+2, Page 2/5).  In the case of too many different measurements within a layout, the parts are not flush (sketch 1, optimal), but rather the work pieces are moved to one side (sketch 2).  Due to this displacement, irregular film stretching occurs, which can lead to folds and holes in the film during the forming process.
In each case, sufficient distances (2”) between parts and table edge (under pressing frame) must be observed. Depending on press system and mill geometry of work pieces, the height of the pedestals could also be of significance.
Here, the same rule applies: do not choose pedestals which are too small; instead, aim for height of 5/8” or ¾” (sketch 3) as an optimal height.

 
Possible pressing errors and correction measures

 
Possible pressing errors and correction measures

Process Parameters For Thermoform Presses
Process parameters should be set complying to pressing systems as well as implemented films and mill geometry.
Depending on material type, ascertain an optimal setting of temperature, pressure and time.  The temperature is the most sensitive and critical factor.  Film performance within the press is basically dependent on sufficient and even warming of the film and decides the pressing result.
Further parameters like vacuum, vacuum speed and pressing times are to be adjusted according to individual variables.
Film warming or reaction of the adhesive is regulated on the one hand by the adjusted heating plate temperature and one on the other hand by the time period of the temperature regulation.  Through experiments and changes to the combination of these two variables, most processing faults or problems can usually be corrected.
Malfunction and errors are caused by temperatures which are too low and/or preheating periods which are too short just like temperatures which are too high and/or preheating periods which are too short.

Overview: Possible pressing errors and correction measures
Fault type
Cause
Measure

Fold formation and / or glossy areas on the fronts (area)
Film did not lie evenly against he heating plate or the membrane in the preheating period and was unevenly heated
Increase vacuum / support air at the membrane / heating plate and / or change the temperature time combination

 
Laying pattern is not optimal.  Pressing table not fully covered, therefore film hangs loose in uncovered areas.
Change laying pattern.  Cover table completely, if necessary, use blind pieces.

 
Film is formed too slowly, resulting in selective pre-adhesion in single places.
Increase vacuum speed

 
Membrane not installed correctly, tightened unevenly.
Re-tighten membrane.

Fold formation in the corner / edge areas (table cloth folds)
Film surplus between work pieces, surplus material is not completely pulled away.
Increase distance between parts.  Possible vary height of under layer.  Optimize table layering.

Corner adhesion insufficient / loose corners.
Adhesion coating missing or too low.
Apply adhesive according to manufacturer’s specifications.

 
Work piece has moved on the underlayer / pins.
Check table layering.

Film does not adhere to countersinks.
Wrong temperature settings, film is too cold.
Check parameters.

 
Adhesive coating too low or initial adhesion too small.
Observe specifications of adhesive manufacturer.

 

Overview: Possible pressing errors and correction measures
Fault Type
Cause
Measure

Holes in the film / film tears
Temperature too high, film is overheated (film melts)
Reduce Temperature

 
Film is too cold and tears, rough irregular edges (cold tear)
Increase temperature

 
Vacuum time is too short, film is formed too quickly.
Reduce forming pressure and / or speed.

 
Film was stretched too strongly, as distance between parts was too small.
Enlarge distance between parts, or optimize table layering.

 
Work piece has been displaced or pedestal is wrong.
Reposition work piece, or renew pedestal.

Lightening of corners / thinning of film
Film is stretched too thin.
Increase part distance and / or decrease height of underlayer

 
Film is fixed at corner radius (transition zone of surface to edge) and pulled down too far.
Corner radius too peaked, film “locks”.  Round off edges slightly.

 
Film is formed too coldly (“crazing”)
Increase temperature


 

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Are you breaking membranes?

12/28/2019

1 Comment

 
Membrane presses such as made by Wemhoner and Burkle or even as an add on for Almex, Italpresse or Orma utlize rubber or silicone membranes to both transfer heat and to apply positive pressure on the components being pressed.

Types of membranes
There are various types of membranes such as rubber and silicone. Rubber membranes are less cost but are harder and do not get into the routered out profiles as well. Silicone membranes are softer and able to press into the profiles better however can be brown to tearing and blowing out. With silicone membranes you can different shore types which means different hardnesses as well as different thicknesses. Some manufacturers utilize different color membranes to signify different hardnesses however that is only to tell them apart.

It should be noticed that membranes can come textured on one side and smooth on the other or rough both sides, smooth both sides. Manufacturers sometimes apply the textured side towards the components because they find that  it releases the sticking and enables the vinyl to move and not get trapped under the membranes pressure. Doing this can sometimes transfer the texture to the components surface giving the component an unintended fabric like appearance. 

Why membranes are blowing
Membranes do have a certain life to them based upon constant stretching. Usually this is measured in cycles however you might shorten the life by how you use the membrane. Below are various ways you might shorten the life of a membrane. 

1. Sharp corners: Some companies press cabinet sides or components with too sharp corners. This can drastically reduce the life of your membrane. An alternative solution is to flat laminate panels via  2 part epoxy using a glue spreader or a PUR lamination line. The second solution is to design your components with a more eased edge to lengthen the use of your membane. 

2. Component spacing: The next thing that can damage a membrane is leaving too much distance between the parts. You can use a jig or long dummy components and this will keep the vinyl from over stretching or sliding across the table as well as the membrane from pulling too hard on the corner. Another issue can be having the components too close to each other but this is a less common issue.

3. Membrane tension: It is important to have the right tension of the membrane installed on your press and this is based upon the hardness of your membrane and type of press you have. This will require some trial and error.

4. Press settings: When I work with companies to dial this in I usually figure out how they are using their press now and what settings that press has. The membrane should have an adequate temp and not be too hot or too cold. Based upon the settings there may be ways to let the heat and vacuum stage to do a bit of the work. This seems like a small thing but based upon hundreds of cycles the settings can work your membrane a bit less.

I hope that you have found this article helpful and be sure to share with me your tips by commenting and if you are having issues simply email me your press settings. 
1 Comment

Vac-u-clamp press settings, FT 900 and FT 1200

12/17/2019

0 Comments

 
This new series of FT 900 has a 48 cfm pump and 1200 has a 75cfm pump. When pressing with a vacuclamp vacuum press it is typically done at 165 degrees with a 215 to 225 temperature for pre heat for 60 seconds then press for 90 seconds. The cool down time is 30 to 45 seconds.

If you get dog ears on the corners, increase the temp by 5 degrees and the press time by 10 seconds. If you get wrinkles you typically will reduce the heat and/or time. 

In general, when giving press assistance Dackor typically starts with the settings you have and then helps you adjust from there to get the best results. Please let us know your settings and what issues you are having by email and we can trouble shoot.
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    Design Life blog

    Color inspiration from around the world, backstories on design inspiration and informative articles about marketing, membrane pressing and personal development. Author Mark Viers  delivers fresh content that will help you and your business grow and thrive.  

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