It is possible to process our range of panels in both on site and off site situations depending on the project requirements, within this page we will give guidance on tooling and processing applicable. For off site fabrication Valcan can hire out suitable equipment to contractors, if this is of interest, please contact the team on +44(0)1278 428 245

The settings and information contained within this page are offered for guidance only and do not constitute a guaranteed performance. Each machine will have its own characteristics and maximum performance guidelines as stated by the manufacturer which should be adhered to over and above the settings offered as guidance below.

Valcan have partnered with CNC tooling company LKH Tools to ascertain best practice in this area however for beam saw cutting the blade will vary from machine to machine and therefore the below information is initial guidance only. All guidance noted below against LKH Tooling is available as a PDF document – please contact the team to request this.

Vacuum hold down (where applicable) and extraction will make a huge difference to how the tools/blades will perform in the material. As with any tool/blade, these tools need a securely held material / component to achieve the correct results. Vibration will result in the premature failure of any tool/blade.

VitraDual and Vitrabond/A2

Off site CNC Cutting and Grooving

VitraDual

Drilling, cut outs and slotting work – dry, no coolant required. Tooling options for 4mm and 6mm diameter:

Tools Required:6mm Diameter – S1-6/6-12-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 6 meters per minute, Increasing to a maximum of 12 Meters per Minute.
Max Depth:3mm single pass
Tools Required:4mm Diameter – S1-4/6-6-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.2 Meters Per Minute
Max Feed Rate:Start at 2 meters per minute, Increasing to a maximum of 4 Meters per Minute.
Max Depth:3mm single pass

V Grooving using ball nose cutter – dry, no coolant required:

Tool Required:B1-10/10-22-55 MP B Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 3 meters per minute, Increasing to a maximum of 5-7 Meters per Minute.
Max Depth:1.9-2.1mm Single pass – Between 0.7-1.0mm of material should remain after grooving completed

V Grooving using 92 degree V shaped tool – misting system required – use soluble cutting fluid mixed 10-1 ratio with water. Can be switched off when cutting with 6mm diameter tool:

Tool Required:ACM 10/10-45-90 DLC
Available from LKH tools –
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 5 meters per minute, Increasing to a maximum of 8 Meters per Minute.
Max Depth:1.9-2.1mm Single pass Between 0.7-1.0mm of material should remain after grooving completed

Vitrabond/A2

Drilling, cut outs and slotting work – dry, no coolant required. Tooling options for 4mm and 6mm diameter:

Tools Required:6mm Diameter – S1-6/6-12-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:3mm single pass
Tools Required:4mm Diameter – S1-4/6-6-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.2 Meters Per Minute
Max Feed Rate:Start at 8 meters per minute, Increasing to a maximum of 12 Meters per Minute.
Max Depth:3mm single pass

V Grooving using ball nose cutter – dry, no coolant required:

Tool Required:B1-10/10-22-55 MP B Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:1.9-2.1mm Single pass Between 0.7-1.0mm of material should remain after grooving completed

V Grooving using 92 degree V shaped tool – dry, no coolant required:

Tool Required:ACM 10/10-45-90 DLC
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:1.9-2.1mm Single pass Between 0.7-1.0mm of material should remain after grooving completed

On site cutting and grooving

It is possible to cut VitraDual and Vitrabond/A2 panels on site using rail/plunge saws with suitable aluminium blade according to machine manufacturer and suitable extraction equipment should be used. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts.

Grooves in panels can be achieved using the the Festool PF1200 or Makita CA5000ZJ with the manufacturers recommended blades installed. Grooving can also be achieved using hand routers.

For the Festool TS 55 saw the blade to be used is the HW 160×2.2×20 TF52 blade and part number 496306. For the Makita SP6000 the blade to be used is the B-09307 165x20mm 56T blade.

The panels to be cut or grooved on site should be placed face down on a clean and level surface, it is recommended that this be a MDF board. The cutting board should be swept of cutting swarf and grit between panels being cut/processing.

For cutting of VitraDual and Vitrabond/A2 panels, the blade should extend approximately 2mm past the sheet into the face of the MDF cutting board – with a suitable sharp blade, single pass should be achievable.

For grooving, the blade should leave between 0.7-1.0mm of material after processing – with a suitable sharp blade, clean groove should be achieved in a single pass.

Ceramapanel

Off site Cutting

Ceramapanel can be cut off site using a variety of tools including beam saws and CNC flat bed routers.

Please note that the Ceramapanel Natural+ and Painted range of boards will need any cut/drilled faces to be sealed with the Ceramapanel Edge Sealant, this is supplied FOC with the panel order, if extra is required please contact the Valcan team on +44(0)1278 428 245 to discuss your requirements. Ceramapanel Natural boards do not require sealing.

For CNC cutting, a 6mm PCD bit can be used, no coolant is required, guidance on settings as follows. A good suitable extraction system will be required.

Tools Required:6mm Diameter – S1-6.0/6-14-50 PCD P – Fibre Cement Board
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:Use ramp plunge – 1 Meter Per Minute – DO NOT USE FOR DRILLING
Max Feed Rate:Start at 1.2 meters per minute, Increasing to a maximum of 2 Meters per Minute.
Max Depth:12mm single pass

For saw blade cutting, the blade should extend approximately 5mm below the panel and only 1 panel should be cut at once. As initial guidance, for a 300mm diameter blade, thickness would be 3.2mm with 6 cutting teeth and saw speed of 2000rpm, feed speed will depend on machine. The information for saw blades shown is guidance only and may vary from machine to machine, it is important that the operator of the saw has a good knowledge of the equipment and how the settings affect cutting of various materials.

On site cutting

On site cutting can be achieved using rail/plunge saws with suitable fibre cement blades according to the machine manufacturers guidance and suitable extraction equipment should be used. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts.

For the Festool TS 55 saw the blade to be used is the DIA 160×2.2×20 F4 blade and part number 201910. For the Makita SP6000 the blade to be used is the B-22997 165x20mm 4T blade.

The panels to be cut on site should be placed on a clean and level surface, it is recommended that this be a MDF board. The cutting board should be swept of cutting grit and dirt between panels being cut/processing. The blade should extend approximately 5mm past the sheet into the face of the MDF cutting board – with a suitable sharp blade, single pass should be achievable.

Drilling of Cermapanel

Drill panels 1 at a time using hardened steel bits. All panels should have a minimum of 1 fixed point per panel and the rest sliding points, the fixed point should be central as the panel dimensions allow.   If a panel needs to have 2 fixed points by design, these fixed points should be located on separate carrier rails and located as near as possible to the horizontal central line as, if no central row of fixings are available, use the nearest row. If more than one rail is available behind panels, use the centre most rails for fixed points. On panels with no centre rails, the standard T rails should be swapped out for two separate L rails to prevent fixings of adjacent panels to same carrier profile. Another alternative is to use a top-hat profile for fixing.

If you are looking to purchase any of the tooling or equipment listed on this page, please contact the Valcan team on on +44(0)1278 428 245 or enquiries@valcan.co.uk and we’ll be happy to assist with supply and support.