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ESLON®-DC ESD Polycarbonate - Fabrication

Processing Instructions

ESLON®-DC-Plates can be processed with common plastic methods. The following information is intended to serve as a guideline.

1. Cutting and Machining
ESLON®-DC ESD Polycarbonate plates may be cut with either a band saw or a circular saw. Generally, it is recommended to use the standard cutting speed for plastics. If possible, please use high speed machines (high cutting speed and reduced feed rate) in order to achieve clean cutting edges. For ESLON®-DC ESDPolycarbonate, uncrossed or carbide tipped saw blades are recommended. In order to avoid scratches on the surface, only remove the protective film after processing. When drilling ESLON®-DC ESD Polycarbonate plates, slightly reduce drilling speed in order to avoid hairline cracks, which may appear around the perimeter of the drill hole. The use of twist or tap drills is recommended.

2. Forming and Bending
ESLON®-DC ESD Polycarbonate plates are especially suitable for the forming of covers and hoods and for edge bending. However, we do not recommend fabrication methods such as vacuum forming or deep drawing. These processing methods will expand the conductive coating, which may cause the loss of the static dissipative properties of the sheet. Please find the recommended forming temperatures listed below.

Heat Bending (Heating by IR Heating Rods) Forming  (Circulating Air Oven)
Heat Supply: to 3mm single-sided, otherwise double-sided Recommended minimum plate thickness
Plastic Type
Temperature
3mm
5mm
10mm
Plastic Type
Temperature
M min
Polycarbonate
150°C-160°C
3-5min
5-8min
5-8min
Polycarbonate
145°C-160°C
5mm

Generally, edge bending of ESLON®-DC ESD Polycarbonate plates should be performed at a lower temperature range. Whitening around the surface edges may indicate overheating, however, the static dissipative performance of the sheet will not be affected. By all means, it is advised to perform preliminary bending tests in order to determine the optimum machine settings prior to processing.

When heat bending ESLON®-DC ESD Polycarbonate, please keep in mind that generally temperatures should be lower than for standard materials in order to prevent any surface whitening around the bending edges. Generally, surface whitening indicates an overheating of the material. However, electro static conductivity only slightly decreases along the bending edges (approx. 108 ~ 109 Ω).

When heat bending the ESLON®-DC ESD Polycarbonate Standard version, the protective film may remain on the material on each side. ESLON®-DC ESD Polycarbonate Hard Coat may only be heat bent after the protective film has been removed.

ESLON®-DC ESD Polycarbonate Standard versions may be bent up to an angle of 90, the ESLON®-DC ESD Polycarbonate Hard Coat version may be bent up to an angle of 70. Cold bending of ESLON®-DC ESD Polycarbonate Standard is possible. We strongly recommend to conduct bending tests with sample strips in order to calibrate the fabrication machines accordingly.

3. Bonding
Prior to the application of the adhesive, please make sure that the parts to be joined are prepared correctly. For the ESLON®-DC ESD Polycarbonate Standard version, the conductive coating must be removed from the surface area with an acetone-soaked cloth in order to ensure adhesion. For ESLON®-DC ESD Polycarbonate Hard Coat, the conductive coating must be removed mechanically, i.e. by milling or grinding. The remaining surface area should be covered with a tape in order to avoid any unintentional chemical damage to the conductive coating. For best adhesion, it is recommended to bevel the edges to be glued and so to increase the contact area. In order to facilitate the application of the adhesive, the surface area where the conductive coating is removed should be 2-3mm larger than the plate thickness of the counterpart.

Compatible Adhesives for ESLON®-DC ESD
Type of Material Adhesive
Polycarbonate Solvent-based methylene chloride adhesives, subsequent baking necessary

If necessary, it is advisable to roughen up the surface for better bonding. Cyanoacrylate adhesives may be used on smaller parts. A precision spraying device or fine brush is recommended for the application of the adhesive.

4. Cleaning and Maintenance
For cleaning ESLON®-DC ESD Polycarbonate plates, we advise the use of IPA (isopropyl alcohol, isopropanol), alcohol-based cleaning liquids or water. Never use cleaning liquids mainly based on organic solvents (i.e. acetone) on ESLON®-DC ESD Polycarbonate Standard. ESLON®-DC ESD Polycarbonate Hard Coat, however, may be cleaned with organic solvents on the sheet surface. Please note that abrasive or corrosive cleaning agents are generally not suitable for any plastic material. Glass and plastic cleaners as well as soap suds are suitable for cleaning ESLON®-DC ESD Polycarbonate.



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