Mustang Sheet Fabrication Guide - Curbellplastics.com

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Cutting/MachiningDrillingDrilling holes is performed best on a drill presswith commercially available plastic cutting drillbits. The bit diameter should be used to determinethe appropriate drill speed (See Table 1).Bit Diameter(inches)1/83/161/43/81/25/8Table 1Speed(RPM)3500250018001200900700Standard‘Twist Drill BitFigure 460-90°ModifiedDrill BitGrind smallflats along thecutting edgePlace a scrap piece of plastic sheet or plywoodunder the sheet that is being drilled. This willeliminate the possibility of chipping as the bitpasses through the other end. Standard twist drillscan be used, provided modifications to the drill bitare made. These modifications will allow the bitto scrape rather than cut through the sheet (SeeFigure 4).Regulate the speed of drilling to obtain acontinuous spiraling chip. Use air or a cool watermist spray if needed. Avoid cutting oils as theymay cause crazing around the drilling area. Refrainfrom creating notches in the drilled areas asnotches and crazing may cause premature failureof the sheet or fabricated part.Cutting and Drilling TipsFor optimum cutting and drilling quality, the belowguidelines should be observed:• Use sharp blades/bits/tools reserved for cuttingplastic sheet• Use proper and constant feed rates and RPMs• Prolong tool life by using the fastest rate of cutto achieve the desired edge or cut quality• Always clamp the sheet being fabricated toeliminate vibration which could possibly causechipping or cracking during cutting/drilling• Compressed air or a fine water mist may be usedif necessary to minimize heat buildup during thecutting and trimming processesEdge FinishingWhen edge finishing is required, mechanical edgefinishing with diamond cutting wheels provideexcellent results. If further edge quality is required,fl ame polishing may be the preferred technique(remove masking prior to fl ame polishing).Bonding Mustang to ItselfTwo-part adhesives are recommended whenbonding Mustang to Mustang. Solvent bondingsimilar to the technique used when bonding acrylicparts is not recommended. There are severaladhesives that have been found to work well withMustang sheet. The following have been evaluatedand work well with Mustang sheet. In order ofeffectiveness:• Weld-On #55• Lord Adhesives #7542 A/B• Flex Welder 14345• Lord Adhesives #403/19• Lord Adhesives #406/19• Lord Adhesives #406/17• Plastic Welder II #14340• Cybercryl #812• Weld-On #58Two-sided pressure sensitive tapes such as 3MVHB bonds well to Mustang.7
Cutting/MachiningAdhering Mustang to Other MaterialsCare should be taken when bonding Mustang toother materials. Slight differences in thermalexpansion and contraction characteristics couldplace a large concentrated stress on the bondedarea. If Mustang must be bonded to dissimilarmaterials, bond as small an area as possible usingadhesives that remain fl exible after curing.Below are recommended adhesives forbonding Mustang to other materials. In order ofeffectiveness:Mustang to PolycarbonateLord 7542 A/BWeld-on #58Loctite 3922Loctite 3321Loctite 3106Dymax 3094Lord 406/19Dymax 3015Plastic Welder II #14340The adhesives listed for Mustang to Mustang,and for bonding Mustang to other materials, havebeen evaluated and are recommended. For bestresults, please follow the guidelines for use fromthe adhesive manufacturers.Mechanical FasteningMustang to AcrylicLord 403/19Lord 406/19Loctite 3922Loctite 3106Loctite 3321Dymax 3094Lord 7542 A/BBondmaster V5004Attaching Mustang sheet to itself and othersubstrates can be accomplished with varioustypes of mechanical fasteners. However, whenexposed to fluctuating temperatures, allowancesfor expansion and contraction must be included.Drilling oversized holes, using rubber-coatedwashers and spacers to distribute localized stressand to act as a cushion to the fastener, as well asnot overtightening the fasteners, will allow thesheet to move and assist in the prevention ofpremature failure at the bonded area. Use onlynon-rusting fasteners, such as aluminum pop rivets,and space the mechanical fasteners far enoughapart to avoid localized overstressing inthe attached area, but still close enough to carrythe expected load.DecoratingMustang sheet can easily be decorated using signpaints manufactured for use on plastics. Followthe paint manufacturer’s guidelines for optimumresults. Always use proper fabrication guidelinesprior to painting and make sure that the Mustangsheet is clean of dust, dirt, grease, oily residues,and grime. All of these will affect the level of paintadhesion and the performance of the finishedproduct. A 1:1 mixture of water and isopropylalcohol works well for the oily residues that areresistant to mild soapy water. Use a soft cottoncloth to rub lightly and dry.Mustang sheet works exceptionally well inpre-decorated applications where thermoformingis necessary. Because pre-drying isn’t required,the lower thermoforming temperatures, improvedmaterial distribution and stretching characteristics,Mustang sheet is fully compatible with vinyland screen inks that are designed forthemoformed signs.When using the spray and cut maskingtechnique, care should be taken not to cut theMustang sheet surface when cutting throughthe masking. This could cause notches, whichmay result in premature failure of the sheet orfabricated part. It is suggested that the blade tipof the cutting instrument be rounded to preventaccidental notching.Paint typically reduces the impact strength of allplastics. Design considerations should be taken intoaccount to minimize the potential for cracking andpossible breakage of the finished part.General guidelines include:• Avoid too wet a mist when spraying• Allow proper drying time between coatsof paint (refer to paint manufacturer’srecommendations)• Avoid application of heavy wet coats of paintduring each application• Use dry air during the spraying process aswater can affect the adhesion and strengthof the paint film• Avoid high humidity areas during the paintcuring process8
Page 1 and 2: Fabrication GuidebyCurbell Plastics
Page 4: Mustang FeaturesTemperature Resista
Page 7: Cutting/MachiningBlade Diameter (in
Page 11 and 12: FormingLine BendingLine bending, al
Page 14 and 15: Chemical ResistanceChemical Resista
Page 16 and 17: Troubleshooting GuideMustang Circul
Page 18 and 19: DisclaimerThis manual is a general

Mustang Sheet Fabrication Guide - Curbellplastics.com

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