One of my designers wants a wall (in a chapel) to be a metal panel, about 4 feet by 5 feet. We looked at using a metal laminate, but the edges are an issue. She wants the edges to be seamless, wrapping around the 1 inch thick core (with 1/8 inch radii or less) so that the panel appears to be a monolithic slab of bronze metal. The questions are: (1) can the laminate do that; (2) can a metal do that (be laminated to a core and self edge); (3) if we use the metal, what gage would work best; (4) is oil-canning an issue we need to consider; (5) what haven’t I thought of?
Help is greatly appreciated - and quickly. The instructions to the contractor went out last night, and if we need to change the change, it should happen ASAP.
If you truly want a monolithic slab of bronze, I’d use a heavy gauge of bronze sheet, form it, braze it, and skip the wood core. (Is this going to be polished as a maintenance item? Tarnishing from fingerprints and what have you will be an issue.)
But, could you really discern the edge of plastic laminate in an objectionable way? What’s the viewing distance?
A plastic-core composite material may be an option (e.g. Alpollic), I know it exists in copper, but I don’t know about bronze. The corners would be slightly open with this product.
Chemetal makes non-backed (no phenolic) metal laminates, but I don’t know if they have bronze. You could also laminate bronze sheet to wood, I suppose.
This is the type of thing I think you want to get a fabricator involved with, so the methods and results can be discussed with someone who does it. I’m thinking a metal craftsperson, not necessarily a woodworker.
It’s not only the edges that are an issue, but even more so the corners (if they are visible), where two returned edges come together. Making that joint seamless/invisible with thin metal is not realistic. Would need to be brazed or soldered, then ground smooth and the surface finish restored. Won’t happen with thin metal.
Have you considered using a metal composite material like Alucobond or Alpolic? They can form the seamless edges, but the corners could be problem. Also, the 4mm thickness would also help avoid any potential oil canning.
3M has an interesting film, Di-Noc (www.dinocfilm.com, http://snipr.com/1zm72), that is quite convincing. It comes in a wide variety of fake (faux, if you prefer) finishes, can be used interior or exterior, even on the floor. If you didnt need a metallic sound, the core could be gypboard.
Perhaps the LuminOre products would work. See http://www.LuminOre.com. I do not have personal experience with this product but it looks like it could provide the look your designer wants.