Laminated plywood combines the characteristics of timber (for example, Birch) with the benefits of film lamination, resulting in a durable and well-looking product. Available in various grades and thicknesses, it can be used in various applications - from flooring to intricate joinery.
The laminated structure provides exceptional stability, making it suitable for both structural and non-structural use. Waterproof adhesives reduce the risk of delamination in humid environments.
How Laminated Plywood is Manufactured
Laminated plywood is produced from raw plywood by pressing laminate or film to the surface. The process begins with picking high-quality logs, known for fine grain and strength. These logs are machined, debarked and pealed into veneer sheets, typically 1.4mm thick (for Birch, Alder, Beech). The sheets are dried then to a moisture content of around 8-12%.
The drying process is crucial to ensure strong adhesive bonding (such as phenolic or urea-formaldehyde) and prevent warping. After applying the adhesive, the fully dried veneers are layered in different orientations (it is called cross-lamination) to enhance strength and stability and counteract any warping tendencies.
The layered veneers are placed in a hydraulic press under heat and pressure to cure the adhesive and bond the layers into a solid panel. After pressing, the plywood is trimmed to size and sanded for a smooth finish. It may be coated or sealed for added protection and aesthetic appeal.
While it is lighter than solid wood, laminated plywood can still be heavier than many of lightweight materials.
Types of film for Laminated Plywood
Melamine Films
Melamine-impregnated films are created to offer a smooth, but hard surface that is resistant to heat, scratches, and stains. Those are mainly used for furniture and cabinetry.
Phenolic Films
These are highly durable and weather resistant. They provide strong protection against wear and are a smart choice for surfaces exposed to harsh conditions and heavy used.
PVC Films
Polyvinyl chloride (PVC) is flexible and provides a variety of finishes and textures for decorative applications. However, PVC films offer lower level of durability than phenolic or melamine films.
Decorative Laminates
These laminates are available in a range of colours and patterns. They give some protection to the plywood surface and offer an aesthetic appeal.
Metallic Films (Aluminium)
Aluminium overlay provides exceptional strength and rigidity. This makes these films ideal for decorative applications, or where heat insulating and air-tight surface is required.
Thermoplastic Films
The heat-activated films provide a smooth finish and are mainly used in applications where a seamless appearance is needed.