There are a number of different types of machines for contour edge-banding. In this article we compare them and explain the pros and cons of each method. The goal is to help you make an informed decision about the right machine for your situation and mix of work.
There are three main categories of contour edge-banding machines:
Manual machines have a rotating roller and a glue application system. There are two types:
Manual Contour Edge-Bander – Stationary
Manual Contour Edge-Bander – Hand Held
In each case the operator is applying all of the pressure and controlling the angle of the pressure.
The advantage of these machines is low cost.
Disadvantages are:
It’s difficult for an operator to apply sufficient pressure. This means that, often, more than one person is required, especially when dealing with large panels.
As a result the glue bond is weaker, so you usually need to use Flex Edge to enable smaller radius corners with consistency.
Butt joins have to be overlapped and then trimmed manually which is time consuming and quality can vary.
Semi-automatic machines use pinch rollers to rotate the panel around a fixed banding head. They use the angle of the pinch rollers (like an angled power feeder) to apply pressure against the edge as well as to rotate the panel.
Semi-Automatic Edge-Bander
The advantages of this system are:
The disadvantages are:
For these reasons semi-automatic machines are also very dependent on operator “feel”, which means quality can vary between operators.
Because these machines can use only very flexible edge banding material, they usually require the use of Flex Edge. Flex Edge is a very soft material that makes it easier to bend around smaller radiuses. However, Flex Edge:
Typically Flex Edge is made from PVC and is not available in “greener” recyclable materials such as ABS and Polypropylene
Butt joins are not as accurate or repeatable as fully controlled automatic machines.
There are 2 types of fully automatic machines:
The Vector Revolution machines use a patented pressure system utilising artificial intelligence (AI) algorithms to automatically analyse the shape of the panel as the head progresses around the panel. It requires no programming.
Curved Edge-Bander
The advantages of this system are:
A further advantage of the Vector Revolution principle is that it is fully compatible with nested based manufacturing. With shaped components, enormous time and material savings can be made by nesting the shapes. The Vector Revolution principle then easily performs the edge-banding processes without any issues of panel alignment on the machine.
Nested Parts – a capability of the Vector Revolution Principle
The disadvantages compared to CNC hybrid contour banders are:
Advantages of a dedicated contour bander with separate CNC machines for cutting the panels are:
The CNC hybrid contour edge-banders use a CNC program to first cut the shape then, because it knows the position of the panel, use a second CNC program to carry the edge-banding head around the panel. This is followed by trimming and scraping.
CNC Hybrid Contour Bander
The advantages of this system are:
The disadvantages are:
These machines are ideally suited to high value components such as high end office furniture. It can be difficult to get an economic return producing high volume mid range and low end panels such as closets, school desks, store-fixtures and the like.
As businesses look to differentiate their products from competitors, shaped panels are making up a greater proportion of components manufactured in the joinery industry. This is evident by the high number of new manual machine manufacturers in the world as demand for entry into this field increases.
The opportunity to create new products and designs with contoured panels means manufacturers have many new possibilities to present a range, which takes them away from the commodity areas of box based components, and differentiates them from competitors.
Interesting Design Using Curved Components
It’s also common to hear that ‘cut and clash’ component suppliers (those supplying to other manufacturers), who invest in contour edge-banding equipment, win contracts they couldn’t win before, because they had now overcome their inability to reliably produce shaped components.
Contour banding is a whole new learning experience but worth the effort as it opens up new market opportunities with increased margins.
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