Success through state-of-the-art lightweight

construction technology

A member of the HOMAG Group

HOMAG Holzbearbeitungssysteme AG
Homagstraße 3 – 5
72296 SCHOPFLOCH
GERMANY
Tel. +49 7443 13-0
Fax +49 7443 13-2300
info@homag.de
www.homag.com
 The trend towards greater mobility in our lives and the underlying need for
functional furniture design have created a demand for new materials.
Innovative wood-based material solutions combine the benefits of low
intrinsic weight with high levels of strength, offering almost unlimited scope
for design. The lightweight sandwich construction of these new materials has
laid the foundation for the furniture design of the future. One material, a whole range of new possibilities
02
Success through lightweight
construction
The lightweight panel used in the
furniture and structural element
industry is among the most significant
material innovations of recent years.
Given the soaring cost of energy and
raw materials, more efficient furniture
production has to be the way forward.
Modern lightweight panels reduce raw
material consumption without
comprising either stability or strength.
HOMAG technology supplies the
innovative methods and sustainable
solutions needed to put these
theoretical benefits into practice.
Ecological benefits
The lower proportion of wood materials
used in lightweight panels means more
sparing use of our forestry resources,
and so contributes towards nature and
environmental conservation. The effec-
tive use of wood and energy also adds
to the economy of your production.
Patented expertise
HOMAG makes available technical
processes which ensure outstanding
economy. Through control of the entire
process chain, we are able to ensure
that all lightweight construction
methods are deployed to their very
best advantage. Make use of our
comprehensive pool of expertise in
a market segment which promises
outstanding potential for growth.
03
Modern material mix
A growing variety of materials used in
production calls for new solutions in
fields such as automotive engineering
or trade fair stand construction. The
furniture sector, for instance, makes use
of lightweight construction panels with
paper honeycomb core. HOMAG offers
a range of suitable technologies for
producing friction locked or positive
locked panel connections and mounting
the relevant hardware.
New table, bed and cabinet
designs
Another outstanding benefit is the
exciting scope for new design ideas.
The functionality of the new material
is evidenced by its broad range
application possibilities. One thing is for
certain: Lightweight construction panels
will play a key role in the future not only
of fitted kitchen construction and
furniture production but also trade fair
design and interior fittings. Manufacture
is possible in practically any optional
thickness or format.
Cost-efficient logistics
The minimal material weight will mean
the capability to construct lighter
furniture which can be more cheaply
transported. Improved utilization of
available loading capacity and lower
weight will reduce freight costs consi-
derably. Customer-friendly pack weights
and easier assembly and dismantling
round off the list of benefits.
The HOMAG Group offers a complete
solution from panel manufacture
through to the finish packaged furniture.
 Just-in-time manufacture of
lightweight panels

Lightweight panel construction variants: The 6 success factors of lightweight panel material

• Sparing use of resources

• Functionality of properties
• Wide-ranging design scope
• Functionality of application
• Optimum logistics
• Ergonomics – weight

04 05
Hexagonal honeycomb Corrugated web Compartmented Polystyrene core Aluminium honeycomb
honeycomb honeycomb (wood) (foam)

Just-in-time production of light- Once these outline conditions are in

weight and sandwich panels place, a plant from TORWEGGE is
capable of producing lightweight
Given the growing trend for smaller
panels economically and cost-
batch sizes and demand for non-
effectively – even in small batch sizes.
standard workpiece production, the
The plants are capable of processing
manufacture of lightweight panels
panels in a broad range of different
must always represent an economic
lengths, widths and thicknesses,
advantage. Depending on the intended
allowing TORWEGGE to offer every
function of the lightweight panel, the
user a practically oriented and
material parameters first have to be
economical optimum solution.
defined. The “inner life” of the panels
can be adjusted on this basis. Where
special static requirements are an
issue, panels with suitably arranged
rails are used.

Cardboard honeycomb

Facing

Rail
TORWEGGE PWR 500 – Plant for composite and lightweight panel manufacture
 Impressive in form
and function:
Edge closure with a
decor edge permits
economical furniture
production with a
solid appearance.

06 07

Edge closure
Types of edge closure:

A greater degree of independence when it comes to material selection makes for more flexibility

in production. Lightweight construction poses a special challenge when it comes to edge closure.

This is why we offer our customer a varied choice of different edge closure methods. From the

conventional rail as a basic solution through to the progressive support edge. Whether kitchens,

living rooms, bedrooms, offices or shopfitting, trade fair stand construction or interior fittings –

HOMAG has a specially tailored solution to offer for your specific application requirement.

Lightweight panel with rail Lightweight panel with thick edge Lightweight panel with SupportEdge

Lightweight panel with support and decor edge Lightweight panel with extruded edge (EXKA)
(DoubleEdge / patented)
 Edge closure for honeycomb panels with rails

Edge closure for honeycomb panels

with rails

• Conventional technology
• No new investment required
• No additional technology required
• No additional support material

08
06 09

Panel manufacture with No additional gluing units

integrated rails
Edge banding is carried out on
In this variant, the rail is inserted during standard machines. All types of edges
manufacture of the panels. Edge closu- can be applied without problems in the
re is achieved without the need for any same way as for conventional panels.
additional technology, eliminating the
need for investment in new facilities.
Conventional methods are sufficient.

Material specifications:

Panel thickness: max. 100 mm

Decor edge: _> 0,4 mm
Rail for “support” function
 Edge closure with subsequently glued-in rail
Gluing in of rails
Large-format honeycomb panels can
be divided on a just-in-time basis and
the rails subsequently glued in. This
processed developed by HOMAG
permits rails to be glued subsequently
into honeycomb panels in response to
individual customer order.
Edge closure with subsequently
glued-in rail
• Same outline conditions as for chipboard
• Decor material can be chosen irrespective
of lightweight panel
10
Starting point: Standard commercially available
large-format lightweight panel
4. Trimming the glue pockets
5. Laying glue beads
Support function
The decor edge measures more than
0.4 mm. The maximum panel thickness
is 100 mm. The rail has a “support”
function. The decor edges are glued in
using the same outline conditions as for
chipboard.
11
1. Squaring the divided honeycomb panel
2. Trimming grooves above and below
3. Clearing out the honeycomb core
6. Gluing in the rails
7. Flush trimming
 Edge closure with thick edges for
rail-less honeycomb panels

• Conventional technology
• No new investment required
• No additional technology necessary
• No additional support material

Edge closure with SupportEdge

(for rail-less honeycomb panels)

• Conventional technology
• Little new investment required
• No / little additional technology necessary
• No / little additional support material

12 13

Edge closure with thick edges in rail-less Edge closure with SupportEdge for rail-less
honeycomb panels honeycomb panels

Without additional technology On standard machines Minimal new investment

This type of edge closure does not
require any additional outlay.
It allows you to work with existing
technology and eliminates the need
for new investment.
Edge gluing takes place on standard
machines without additional gluing
units. The facing measures more than
6 mm, the decor edge more than
2 mm. The maximum panel thickness
is 100 mm.
The support edge and decor edge
are glued using a separate process.
Machines with one gluing unit require
two gluing processes. Special
machines can be configured with
two gluing units to allow complete
processing in a single banding pass.

Material specifications: Material specifications:

Facing: _> 6 mm Facing: _> 3 mm

Panel thickness: max. 100 mm Panel thickness: max. 100 mm
Thick edge: _> 2 mm Decor edge: _> 0,4 mm
Central core with dense honeycomb Support edge: _> 2 mm
Core-independent
 Edge closure with DoubleEdge for rail-less honeycomb
panels (patented) – the most economical solution
Reduced process time
This new and innovative technology
represents the most economical solution
for narrow surface closure of rail-less
honeycomb panels. Support edges and
decor edges are banded in a single
pass. When working with shaped
components, consequently only a single
work process is necessary. This allows
a 40 % reduction in process time to be
achieved relative to complete processing
(sizing, edge banding and edge finish
processing).
14
Material specifications:
Facing:
Panel thickness:
Decor edge:
Support edge:
Core-independent
In a single work process
A DoubleEdge gluing unit can be
mounted on standard machines. The
facing is more than 3 mm, the support
edge more than 1.5 mm and the decor
edge more than 0.5 mm. The panel has
a maximum thickness of 60 mm.
DoubleEdge
• Improved economy due to fewer
processing steps
• Banding support edges and decor edges
in a single work process
15
_> 4 mm
max. 60 mm
_> 0,5 mm
_> 1,5 mm
 Edge extrusion with EXKA

• Capacity to withstand high levels of

mechanical stress
• Joint-free abutting edges
• Fulfils high design aspirations
Edge extrusion with EXKA
• Moisture protection

16
Joint-free abutting edges
The processing centre with extruder
(patented) permits the use of different
plastic granulates (PE, PP etc.) injected
into the cavity in the panel edge area.
This allows lightweight panels to be
edged, for instance with aluminium
decks just1 mm in thickness. Edge
extrusion permits a joint-free abutting
edge and also opens up scope for
exciting and innovative design.
17
Optimum edge protection
Edge protection with EXKA offers
scope for withstanding high levels of
mechanical stress and outstanding
moisture protection, e.g. for laboratory
furniture. Coloration of the material can
be used as a design element. The
edge compaction of chipboard leads
to considerable material savings.

Extruded edge
Material specifications:

Facing: _> 0,5 mm

Panel thickness: max. 30 mm
Core-independent

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Making a mark with the very best connections
Panels with rails
For different panel structures, different
connectors have to be used. Panels
with rails permit the use of standard
hardware, meaning that no new fittings
are required. However, in this case the
design must take the position of the
rails into account (free positioning is
not possible).
Panels from 4 mm
facing
• Hardly any change
to furniture design
• Modified hardware
with special
screws / dowels
• No or only
minimal new
investment
19
Panels with facings from 4 mm
In the case of panels whose decor
facing is thicker than 4 mm, modified
standard hardware can be used. This
solution is suitable for existing produc-
tion processes without new invest-
ment. The furniture design hardly
requires any changes. From a panel
thickness of around 38 cm, this offers
a pricing advantage over chipboard
panels. The strength depends on the
glue connection between the facing
and the honeycomb / the strength of
the facing.
Conventional hardware fixture Special screw (Häfele) Expanding dowel (Top Ten) Ultrasound welded dowel (Titusonic)
PANFIX expanding dowel Expanding / adhesive dowel AEROFIX 100
(Zimmer Kunststofftechnik) (Häfele / Zimmer Kunststofftechnik)
 AEROFIX 100
• Optimum pull-out resistance of hardware
screws irrespective of the glue bond
between the central core and the facing
• Immediate capability to withstand stress
permits continuous further processing
• Manual and automatic application possible

20 21

The new solution

Panels with facings up to 4 mm The new AEROFIX 100 permits

immediate further processing by
Both facings must be connected, as
means of additional mechanical
the pull-out strength of one facing is
expansion. Using the integrated glue
insufficient. Adhesive dowels work
cartridge, the system can be used
according to a principle whereby an
on both a manual and an automated
area is filled in with PUR compound /
basis. This variant can be used
glue to allow a screw to be mounted.
industrially on processing centres
There is hardly any need to alter the
and throughfeed drilling machines.
furniture design. Fixing points can be
freely positioned. The strength does
not depend on the glue bond between
the facing and the honeycomb. In
terms of workmanship, the principle is
simple to implement – similar to using
a K2 foam for mounting an internal AEROFIX 100 expanding dowel with integrated AEROFIX 100 pre-assembled (as-delivered status) Anchored under the upper facing due to
door. glue cartridge expanding action

Dowel is glued to both facings Immediate hardware mounting using standard

screws
 Panel manufacture Sawing Surface lamination Sizing and edge banding Drilling and hardware Assembly / Packaging

Starting situation Panel dividing Panel coating Narrow edge closure Hardware technology Assembly

Decor edge on rail

Surface coating

Individual lightweight panels

with frames (TORWEGGE) THROUGH-
FEED
TECHNOLOGY Conventional Special screw
STRAIGHT hardware fitting (Häfele)
Gluing in rail Surface coating Decor edge on rail
WORKPIECES

Expanding dowel Ultrasound welded

(Top Ten) dowel (Titusonic)
Support edge in Double edge
Large-format frameless lightweight Panel dividing rebate and decor edge without rebate
construction panels (e. g. Egger, Eurolight)
Thick edge
without rail
STATIONARY
TECHNOLOGY Expanding dowel PANFIX
SHAPED (Zimmer Kunststofftechnik)
COMPONENTS
Support edge in rebate Double edge without
and decor edge on rebate on shaped
Thick edge on
shaped components components
shaped components

EXKA on shaped components Expanding / Adhesive dowel AEROFIX 100 /

(edge extrusion) (Häfele / Zimmer Kunststofftechnik)

22 23

Lightweight construction technology from the

HOMAG Group
The HOMAG Group offers wide-
ranging technologies for edge closure
and fastening technology – ensuring
the economical deployment of light-
weight construction materials for your
production.

Edge closure Hardware fastening methods

Automatic
Edge banding machine Processing centre Manual Processing centre drilling and dowel driving machine

Gluing in rails Conventional fastening

x -- methods for honeycomb x x x
panels with rails

Thick edge Modified hardware with

x x special screws x x x

SupportEdge Expanding dowels

x x x -- --

DoubleEdge Ultrasound welded

x x dowels -- x x

EXKA PANFIX expanding

-- x dowels x x x

Expanding / adhesive
Photos and specifications are not binding in every detail. We expressly reserve the right to make changes in the interests of further development.
dowels AEROFIX 100 x x x