Precision Board Versus MDF & EPS

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to host guest blogs written by some of the industry’s biggest movers and shakers, posted to the Precision Board Blog. This guest blog is written by Jody Wyse, Western Regional Sales Manager for Hawkeye Industries, manufacturers of Duratec polyester and vinylester coatings, headquartered in Bloomington, California.

In our February Tooling Tidbit e-blast we talked about the benefits of using Precision Board urethane tooling board for soft tooling applications. In this month’s guest blog, Jody discusses the benefits of using Precision Board Urethane Tooling Board over other soft tooling substrates like MDF and EPS.

In Jody’s own words…

My previous blog was about the various Duratec coatings that could be used on Coastal Enterprises’ Precision Board Tooling Board and was a broad discussion of products in general. In this latest blog entry, I will cover the beginning steps for choosing the correct substrate for a tooling project.

Not every tool, plug or shape being made needs a perfect surface. In fact, I’ve used everything from a sheet of 6mil plastic over a dirt shape dug in the ground all the way up to high end metal tools. Both surfaces were the correct ones for the jobs being done.

Tooling board comes into play when you need a reliable and dimensionally stable substrate and you don’t want any unpleasant surprises at a time when it is too late in the process to make simple and cost effective changes. Sometimes the problems don’t show up until the final stages of the project, like when the first part, or the permanent final tool is being pulled from the mold or plug you spent the last month (maybe much longer) and possibly hundreds of man hours building.

People frequently ask about using MDF or EPS foam as a substrate for a plug or tool. These materials work, but it’s not what they were designed for. They just happen to work in non critical parts, and they work adequately at best. The most common reason for using these products is the low upfront cost. Another reason is a low number of parts needed (5 or so identical parts off the shape, and the dimensions are reasonably critical, and so is the finished surface of the final part).

Let’s take a look at each of these materials.

MDF (Medium Density Fiberboard)

MDF is cheap, but the quality and consistency is very unreliable. What you buy today may be very different than what you buy tomorrow. Even sheets in the same stack can have very different properties. One big problem with MDF is that it’s always changing shape. MDF is very sensitive to temperature and humidity. So whatever shape you make today will have changed by tomorrow. This gets worse over time, and the changes can be amplified after the first part is pulled from the shape.

After the first part is pulled from an MDF plug or tool it will normally have changed dimensionally, plus the surface profile typically deteriorates. All the work put into creating a shape with the correct dimensions and surface profile may need to be done again, resulting in delays and more man hours, which can increase the costs rapidly.

EPS (Expanded Polystyrene)

EPS foam is cheap, but it can be difficult to shape depending on the density. Low density EPS tends to crumble or come off in small chunks when using hand tools. It also requires different coatings that are compatible with it to create a surface. One of the bigger disadvantages is its very low strength. Rarely can you get more than one part off of an EPS shape, so it normally is used for only that one part.

Conclusion

This doesn’t mean MDF and EPS should never be used, they just have some very limiting physical properties that may be very difficult and expensive to work around.

Precision Board Urethane Tooling Board can be chosen to meet the exact set of physical properties needed for the job, no more, no less. The experts at Coastal Enterprises can help guide you to the correct product for the current job that will save you both time and money.

Having a substrate that is the same today, tomorrow and next week, is required when the surface profile and shape are important. And if more parts are needed off the same shape, a higher density of Precision Board tooling board can be used to increase its durability.

I make samples to show customers using MDF, EPS and Precision Board so they can see first hand the differences in each substrate and what to expect in the finished shape. I also show them what each surface looks like after the first part is made off of it. They are frequently very surprised at how different the surface quality is after only one use.

In some cases the parts made off of low quality substrates need to be extensively reworked before they can be sold or used for their intended purpose. This usually means the original shape also needs similar extensive rework before another part can be made from it, and that’s only if it survived the de-molding process, which they frequently don’t.

My next guest blog will go into the details of cost effectively choosing the correct Duratec coating(s) to achieve the desired surface properties on different densities of Precision Board tooling board.

Hawkeye Industries is proud to be the master distributor of the Duratec line of putties, primers, sealers, and topcoats. Duratec Polyester and Vinyl Ester products are famous for their ability to cure completely when applied to plug/pattern surfaces. That thin-film, air-cure capability makes Duratec ideal for the composites industry. Check out their website or give them a call at (909) 546-1160 0r (800) 977-0060 if you are interested in more information on how Duratec products work with Precision Board tooling board.

Coastal Enterprises manufactures Precision Board, a versatile, cost-effective and eco-friendly urethane material used extensively in the tooling industry. It is a closed-cell, rigid, dimensionally-stable substrate that is ideal for use in a number of different tooling applications. Request free samples, get a quote or sign up for weekly e-blasts packed with helpful information.

Sawatzky Guest Blog: A Love Letter to 30lb Precision Board HDU

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to announce a series of guest blogs written by Dan Sawatzky of Imagination Corporation, which will be posted on the Precision Board Blog each month. This month Dan Sawatzky goes into great detail on why he prefers to use PBLT-30 Precision Board HDU almost exclusively over lighter densities like 15lb and 20lb. He also talks about using a range of Precision Board densities depending on the specific project, from PBLT-4 all the way up to PBLT-60.

In Dan’s own words…

We love Coastal Enterprises Precision Board! We use TONS of it each year (literally).

Precision Board HDU is manufactured in a wide range of densities. It is measured in pounds per cubic foot. We have used everything from 4lb (PBLT-4) board to 60lb (PBLT-60) board in our shop (Ed note: the highest density of Precision Board is PBLT-75 and the lowest is PBLT-4). Which density we use depends on what we are creating. For quick sculptures (typically study models) which will be covered in sculpting epoxy we love the 4lb. It is so soft we can carve it quickly with a variety of hand tools. We typically keep a sheet or two of four inch thick stock on hand. We have used various weights of board through the years but generally stick with 30lb (PBLT-30) Precision Board. If we have a project (such as a door panel) that is in a high traffic area we will use 40lb (PBLT-40) or even 60lb board. We keep a couple of sheets on hand for projects like this.

The ’standard’ in the sign industry is 15lb (PBLT-15) or 18lb (PBLT-18) board and occasionally 20lb (PBLT-20) board.

While most sign people I know tend to go for the lighter densities (15-20lb Precision Board) we favour 30lb board almost exclusively.

It makes perfect sense to us and the reasons are many.

The 30lb board holds detail superbly and is much tougher than lighter weights. It can be machined at the same quick speeds (typically at 300 inches per minute) with our MultiCam CNC router.

Imagine you work on a sign for many hours. During this process you transfer the almost complete piece to a different work table. There’s a screw laying there which you don’t see. If you are using 20lb board or less you will soon have to make a repair. How much did you save by buying lighter board? If you count your time properly you most likely just lost more money than you might have saved by using lessor boards. The 30lb Precision Board can easily survive those types of bumps and bruises without a scratch. Some people I know use a lighter board and then apply a hard coat to protect it. That makes no sense to me for you lose hard earned detail in the process plus you incur extra material and labour costs as well.

The heavier weight material is easy to sell too. We keep a variety of labeled samples on hand for just this purpose.

When I am explaining to a new customer the quality materials we use in our shop I grab a 15lb or 18lb sample piece and easily run my fingernail into the surface. It leaves a nasty scar. The customer is always shocked. I explain that this is what our competition typically uses. Then I hand a 30 lb sample to my customer and ask them to do the same. It doesn’t leave a mark. I ask the customer if they are willing to pay an extra $50 or $100 for that kind of quality. The answer is always YES! As easy as that I’ve sold them on a premium material and made some extra cash in the process.

We generally keep three thicknesses on hand; 1”, 1.5” and 2”. We have some other thickness left over from previous projects which includes some .5”, 3/4”, and 1.25” which we draw from as needed. It is less expensive to order extra and stock it than to make a panic order and pay a premium for the rush.

Because of space considerations (lack of storage) and ease of handling we keep only one density in stock. We buy once or twice each year – in bulk. For a single sheet our shipping costs can equal the price of the material. When we buy a pallet or two the freight is generally less than three times the price of shipping a single sheet. The savings add up in a BIG hurry! Plus I’ll bet your dealer will happily negotiate a better price when you purchase a large order. And if we order a year’s supply of glues and primer at the same time- those boxes ride for free on top of the pallet for further savings.

We are about half way through our most recent order of Precision Board. We keep it under a roof out in the storage area. Another twenty sheets is kept in the router room for handy access.

Sawatzky’s Imagination Corporation is a small family company that specializes in the design and creation of dimensional signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous national and international awards.

Dan Sawatzky is best described as a creative force and visual storyteller extraordinaire. His art career spans almost fifty years of magic. Dan’s passion is to design and create imaginative places that take people from the normal world to a setting of delight and wonder.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs. It is a closed-cell rigid substrate that does not rot, warp or crack. You can request free samples, get a quote or sign up for periodic newsletters packed with helpful information.

Lighting up Casa Hugo’s Dimensional Precision Board Sign

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to host guest blogs written by some of the signage industry’s biggest movers and shakers, posted to the Precision Board Blog. This guest blog is written by Rex Harrison with Harrison Solutions, based in Ontario, Canada. Rex tells us how he designed and fabricated the dimensional sign for the Casa Hugo Mexican Eatery & Tequileria, a local restaurant, and then fills us in on some tricks to cleanly rout Precision Board and light up different elements of the sign using backlights and halo lights.

Q & A with Rex Harrison…

Tell us what the sign project was?

The project was directed to me through a colleague/friend. We work together on projects occasionally, as he is another craftsman in the realm of signs, He is the man behind Stevensville Pallet Project here in the Niagara Region of Ontario. He was approached by the manager of the Casa Hugo Restaurant because SPP had done a personal job for the manager. SPP felt that this type of project was best suited for me and my approach because of the scope and complexity of the project. Since we work together frequently, he knows my style and quality, so he knew that I was the guy to take care of his customers as well as he did himself.

The owner of the establishment, Dave, was in the very last stages of his pre-opening chaos when he reached out in regards to the sign, so it was crunch time, and we had no time to spare. We discussed his ideas, and his logo and branding, and we came up with a game plan and concept fairly quickly. I initially provided him with multiple examples and drafts, and we narrowed it down and customized it until he was certain that he would get exactly what he wanted. I have always based my approach to customers on the concept that I will get in their head to see their vision and make that happen, regardless of what I had preconceived. I will obviously guide them and suggest certain things based on my experience and knowledge, but ultimately, the customer should get what they want. Nothing would be worse than for a business owner to come to work everyday and have to look at a sign they aren’t 100{afbea94bd31582343c3017644f03ec8d7d8fa2386ecb82c250661e06c0c6e111} happy with. So once we agreed on the final design, I gave him my timeframe of construction and assembly, which was a few days past his grand opening. He knew that he had waited too long for this crucial piece of his business, but I assured him that it would be done proper and would be done before his first big weekend.

Why use Precision Board HDU?

I use Precision Board HDU because of how it machines, how it finishes, how it stays true (no shrinkage, no warping, no rotting, no breakdown), and because of how strong it actually is compared to the other brands. In terms of machining, I use a cnc router table with vacuum hold-down, and the Precision Board cuts so cleanly and maintains a super crisp edge, unlike the other large brands, that appear to be more “plastic” like when cut. The Precision Board sands very quickly and easily, which helps me increase production time, and also helps me keep a very flawless finish when a high gloss coating is applied. And the fact that I can rely on it to be “true” in composition means that I can accomplish complex features with machine level accuracy. Also, the lightweight nature of it makes installation and transportation a breeze. A huge selling feature is that it is environmentally-friendly, and at the same time, isn’t a material that bugs would want to eat into.

What density of Precision Board did you use?

I have only ever used the 15lb density (PBLT-15), because that is strong enough for my applications. 99{afbea94bd31582343c3017644f03ec8d7d8fa2386ecb82c250661e06c0c6e111} of my signs are wall mounted, out of reach of most things that would exert any level of pressure or pulling. But in the event that I needed a stronger structure, I would certainly upgrade to the tougher, higher density Precision Board HDU (Ed note: Precision Board comes in 16 densities ranging from 4lb to 75lb).

What was your routing time with the Precision Board HDU and your speeds and feeds settings?

I used a 3/8″ double-flute compression chip-breaker end-mill from Royce-Ayr to machine the parts for this sign. The feed speed was 100mm/sec, and the spindle speed is 20,000 RPMs with a 4hp spindle. I do the outside cuts in two passes, for two reasons. The first pass may leave behind some debris in the toolpath, and the second pass allows the dust collector to evacuate all of the remaining material, which keeps me from having to clean it manually later. The second reason is that the second pass is only cutting through a very thin layer left behind from the first pass, which allows the suction bed to keep a hold on the parts/letters as if they were still a full sheet and not have the bit fighting against hardly any material while it makes the bottom edge of the part/letter have a perfect face edge.

What brand of CNC do you use? Software? Router bits?

I use a 4′ by 8′ CanCam CNC router table with a 4hp spindle and vacuum hold-down. I use a range of software for different applications, but essentially, my toolpaths are created with Vectric VCarve Pro. And my bits are purchased from Royce Ayr.

What did you prime & paint the Precision Board urethane foam with?

I use Transtar Autobody Technologies paint products on all of my jobs. They are designed for the automotive world, which means they can take the exterior abuse, and will last over time. And it finishes very well. I use a gravity-fed air paint gun for the application of the finishes. Once painted, I applied contour cut gloss white vinyl letters to the face of the Precision Board letters that had been scaled down by 1/4″ to allow for the black border around the white lettering.

Talk about how you lit the HDU letters and skull up?

The large CASA HUGO letters are back-lit and halo-lit, which is accomplished by rebating a pocket into the back of the letter (with the cnc router) deep enough to allow the led strip lighting to be mounted to the walls of the pocket and a layer of 1/8″ clear acrylic that is sealed off with clear silicone. That takes care of the backlighting.

For the halo effect, I simply cut out the letter shape again, this time using the cnc laser cutter and 1/4″ translucent white acrylic. This layer is glued to the individual letters, and once applied to the back wall surface, the light can be seen through the translucent layer and spreads out across the background.

As for the Skull and MEXICAN RESTAURANT & TEQUILERIA parts, they were rebated/pocketed into the Precision Board as well, but from the face down, not the from the back down. Same method of installation with the led light strips, but instead of using 1/8″ clear acrylic to seal off the pocket, I used 1/8″ translucent white, which gives the letters and detail of the skull the bright white glow we needed, to match the larger CASA HUGO letters.

How was the sign installed?

The spot in the wall for the sign had been pre-designed when the building exterior was completed, so I basically had this part pretty easy. I ran the power wires together to a main focal point, drilled a hole through the building ball, which was just a layer of plywood with some sheathing, and into the building through the plastic wall material used inside. I secured the sign panel to the wall using 2″ #8 Robertson exterior screws, which matched the finish of the rusted roof tile background perfectly. Once inside, the power supply was connected and switched on.

Any tips or tricks to using Precision Board HDU?

With the 15lb density Precision Board, I always take extra care when applying pressure when manually sanding prior to the primer coat. Also, I make sure I stay away from anything that might bump into it, as the lower densities can dent more easily prior to a primer coat. I’m sure the higher density boards would be more resistant to these types of things (Ed note: Yes! Higher densities have a harder and smoother surface). Also, when priming the machined parts, the end grain (area inside the board that the machine cut) is porous and soaks up a lot of the primer. Simply apply a thicker layer of primer, or do multiple coats to seal off the end grains.

Rex Harrison is essentially a one-man show, doing all of the designing, purchasing, machining, fabrication, wiring, installation, and service himself. He prides himself on being neurotically attentive to detail, because his work represents how much he wants it to be the best sign his customer could possibly purchase. Rex does more than just signs, ranging from machining parts for other shops in town, creating custom cabinetry, and consulting work for other sign/retail display companies. He can be found on his Facebook page for Harrison Solutions.

Using a Laser to Create a Dimensional Precision Board HDU Sign

Team Williams Printing & Signs used a laser system to cut and engrave a two-sided dimensional sign out of PBLT-15 Precision Board high-density urethane foam. See how they used a vinyl covering during the laser engraving process to preserve the white finish of the primer before painting the HDU.

Mike Williams with Team Williams Printing and Signs used their 150 watt C02 Rose Laser System to fabricate a dimensional sign out of 1″ thick sheets of 15lb Precision Board HDU.

“We’ve been doing dimensional signs with a CNC, but we decided to try using our laser,” said Williams. “It came out good. We were very happy with the results,” he added.

Because the sign was two-sided, they decided to cut one side, flip it over, and cut the other side.

He likes using Precision Board high-density urethane for dimensional signs.

“It’s such a lightweight product and very easy to work with. You can also get more detail and save time using a laser over a CNC because you don’t have to change router bits.”

Williams used an interesting technique to get crisp contrasts to the colors on the signs. He says, “first we primed the Precision Board and then put a coat of vinyl on top of it before we lasered it.” He adds, “that way we could laser cut the vinyl on top of the primer, paint a base coat over that and then peel the vinyl away to reveal the nice white color underneath.”

Mike followed that up with a coat of exterior paint.

For this first laser-engraved sign, Williams dialed his settings back a bit and took his time. Cutting time was about 30 minutes per side with his machine running at about half speed and half power. He cut into the Precision Board HDU to about a quarter to 3/8ths inches deep. Once he was finished engraving, he cut the outside part down at ¾ power. Finally, he did two passes on the final cut so that it didn’t leave a black edge on the material.

The sign was going to be installed as a hanging sign and need to withstand the high Florida winds. Mike drilled it out and attached the hangers using hooks and chains. He pre-drilled the holes and put in metal drywall anchors with a spot of glue.

Mike Williams tells us, “we had 60 knot winds the other day here in Florida, so I’m checking to see if the sign is still hanging!”

We’re happy to report that the Precision Board HDU sign is safe and sound and still firmly attached to the chains!

EXTRA RESOURCE: An extensive guide to Laser Engraving Precision Board HDU

Team Williams Printing and Signs is a full service sign shop in Steinhatchee, Florida, offering magnets, banners, yard signs, boat/vehicle wraps, metal signs, billboards, brochures, letter heads, envelopes, backlit signs and much more. They can be found on Facebook or by calling (352) 398-7480.

Request free samples, get a quote or sign up for weekly e-blasts packed with helpful information. You can view our waterjet cutting playlist on our YouTube Channel.

Sawatzky Blog: Sign Invitational 2020 Update

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to announce a series of guest blogs written by Dan Sawatzky of Imagination Corporation, which will be posted on the Precision Board Blog each month. This month Dan Sawatzky shows off his 2020 Sign Invitational entry, reveals his design for the Coastal Enterprises’ ISA Sign Expo booth, and gives high marks to some of the other people competing this year at the ISA Sign Expo.

In Dan’s own words…

The 2020 Sign Invitational is now only a few weeks away. I suspect this means most of the competitors are now starting to work longer hours on their pieces. With most sign shops being very busy these days time is going to get tight for these folks!

I did my first sketches a few minutes after the theme for this year was announced. On the long plane ride home I worked on it some more and had the concept drawings finished within a week. A day or two later I designed and started machining the first pieces from various weights (Ed note: AKA densities or PCF) of Precision Board. Each week I put in a few hours and made great progress too. Things slowed down some whenever we got really busy in the shop. My goal was to finish my entry by the New Year. I missed that deadline by a couple of weeks but still finished my entry in plenty of time.

My piece is called ’The Snapper’ and is a humorous tribute to the sign painters of old. The well worn model ’T’ truck is perched precariously on the steep gravel road while the sign painter is busy at work on his latest masterpiece. The truck has working headlights and a sound system tucked inside. My friend Jim Wells from Fantasonics Engineering designed a series of marvelous sound tracks of the truck starting and running. It is as humorous as the sculpture and fits perfectly.

In concert with my entry I was also working on a second similar piece that will be showcased at the Coastal Enterprises booth. I put the last touches to this piece today, the second week of February. Coastal Enterprises have been generous sponsors of the event since its inception five years ago. They also promote our display heavily during the ISA Sign Expo show. Thanks!

Most of my fellow competitors are keeping their entries closely guarded but I have seen some of the concept art. Two of the competitors have shared pictures. The quality of this year’s event promises to be higher than ever!

Mo Flint from Atomic Barn Studios entry is still in progress. His piece won last year for the small size category and he will be the man to beat this year without a doubt!

The theme of this year’s contest is ‘Less is more’.

Mo designed a hippo bride with one foot on a scale and her very small wedding dress behind her. Underneath in a layered ‘cake’ are all the wonderful foods she loves and craves! It will be a wonderful piece when Mo is done as he is a master at detail.

Amanda and Rusty Gibbs from Gibbs Graphics in Washington State are first time entrants this year. They have pulled out all the stops to create a very imaginative piece. It looks fabulous in the photos and I know it will be even nicer in person. I can hardly wait to see it!

All of the competitors are looking forward to unveiling their creations at the fifth annual Sign Invitational. We hope that everyone who attends the 2020 ISA Sign Expo in Orlando stops by to vote for their favourite!

The ISA EXPO is April 2, 3, 4, 2020 in Orlando. The Sign Invitational entries will be displayed at the Signs of the Times booth #235.