Composite panels can be shaped using a very simple processing method. The technique, called the routing and folding method, enables a fabricator to produce shapes of various kinds and sizes. A V-shaped or rectangular groove is routed on the reverse side of the composite panel using a disk or end milling cutter.
A thin layer of the core material should be left at the base of the groove, i.e. on the inside of the outer cover sheet. The untouched outer cover sheet can now be bent manually, giving an exact and clean folding line which follows the routed groove. The outer radius of the folded edge depends on the shape of the groove and its depth. We do this with MondoClad, Alucobond Plus and Alucore, and Swiss Pearl.
After the V Groove has been formed, fold the return leg back in one movement. It is recommended that a portable folding tool be used for small panels and a folding machine/bed for large format panels. The initial folded angle should slightly more than the final angle required.