Hylite Processing

Posted on by Chris Bulpitt


Thanks to various processing techniques creative designs for office supply applications, furniture and product design or PoS/PoP displays can be realized with HYLITE®. Individual 3-dimensional applications can be realized with contour cutting, forming and other established processing methods for aluminium composite panels.
Moreover the HYLITE® core material can be used as a hinge that allows multiple bendings without breaking. For this purpose, the aluminium cover sheets need to be milled into oppositely. RWTÜV tested the hinge application for 80.000 damage-free bendings.

With an additional powder coating HYLITE® also fulfills the requirements of special surfaces with higher coating thicknesses (> 30µm) e.g. increased scratch resistance. HYLITE® withstands temperatures between +125 °C and +165 °C (about 15 – 20 minutes) which means that it can be coated with low temperature powder coatings. Maximal temperature exposure is at +165 °C which corresponds to the melting point of the core material.

HYLITE® was initially developped for industrial products that needed to be deep-drawable. The plastic polypropylene core has been selected so that formability is only limited by the aluminium skin layers.

Since the metal content through the cross section of a HYLITE® sheet is low (0.4 mm), the forces needed to apply yield during deep-drawing are low compared to other materials like steel. Thus tool wear and therefore cost of maintenance are lower.

All HYLITE® products with soft skin layers (1.2 mm and 2.4 mm) are deep-drawable. Minimum tool radius should be 6-8 mm depending on the product depth, angle of the arc and tensile forces. Mould removing speed should be about 60 mm per second.


Alloy EN AW 5182 Al Mg 4.5 Mn 0.4
Tensile yield point Rp.0.2: 130 N/mm²
Tensile strength Rm: 260 N/mm²
Elongation at fracture A50: 18%
Deep-drawin force: 5 bar (for d=100 mm equals 4kN)

HYLITE® can also be embossed. However, elongation at fracture needs to be considered. For hard alloys (HYLITE® 1,2 mm and 2,0 mm) it is 4 %. For an embossing with 1,0cm width, maximum elongation of HYLITE® is 0,4 mm. The soft alloy  has a higher elongation at fracture with 18%. Embossing contours are sharper when using the hard alloy, the soft alloy shows softer contour gradients.

For engravings, a stylus can be used for HYLITE® as typically used for all metallic surfaces .The goal is to make the surfaces look mat. Additionally, the roughened surface respectively the deepened lines can be layed-up with pigment paste and then be optically highlighted. The lines can vary from very thin to very wide.

For recommendations regarding tools and machinery as well as for useful hints to receive an optimal processing result, please feel free to contact us!

About Chris Bulpitt

17 years distribution experience for both Amari Plastics and Aalco Metals. Service and customer orientated, always striving for perfection. View all posts by Chris Bulpitt →

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Stephen Webster Plastics
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