Laminates 3/15/2005 NTWA Program

Jack Demonstrated these steps in the March 2005 meeting where he did lamination demonstration.  Photos can be found in the photo gallery.

Laminates commonly referred to as Formica.

Several manufacturers of laminates. Formica and Wilsonart most common in this area.

Made up of layers of paper and plastic melamine, fused into a solid sheet, under high pressure and heat.

Two main types of laminates

• Color is a this thin layer –

Most common type

• Color goes through the entire product –

Difficult to find

Usually special order

Why use laminates?

• Inexpensive
• Mark resistant – writing on it does not leave marks.
• Water resistant – no water rings from glasses on it.
• Cleans easy – avoid using abrasive cleaners and those that contain chlorine.
• Relative durable.
• Flexible in design colors, textures, and application.

Substrates

• Use a manmade product like particleboard or medium density fiberboard.

Expands and contracts the least with moisture changes.

• Can be used on plywood.
• Last to recommend is solid wood.

Expands too much.

• Most substrates should be at least ¾”.

Application

• Use contact cement.
• Apply to both sides of a substrate, unless over 1 ¼”.

Stabilizes the moisture absorption.

Application sequence

1. Back or bottom
2. Sides (short side then longer sides)
   • Most visible last.
3. Top or font
• Cut the laminate at least ½” larger than the area being covered. (1/4” for smaller pieces like the sides or thin edges)
• Assembly line on small parts like drawer fronts.
• Finish edges with the file.
• Soften the corners.

Tools needed

• Fine-toothed file.
• Router (laminate preferred)
• Router bits

Straight

Angled or beveled

• Paintbrush or roller
• J-roller
• Cutter (scoring tool)
• Ruler
• Safety glasses.
• 80 Tooth ATB saw blade.
• Auxiliary table saw fence (Aluminum angle)
• Slip stix – dowels or scraps of wood.
• Clamps

Tips

• Butt joints cut back to back with router and square.
• Order about 10-15% more than needed.
• Be careful handling the laminate.  It can crack.
• If you special order laminate from a store, open the box, inspect it for damage and the proper color and texture.