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Plastic Welding Tools Ltd
Phone: (09) 827 6567
Phone: 0800 603 603
info@plasticweldingtools.co.nz
ACM Panel Kits
ACM Panel Kits
ACM welding for signage and cladding
Aluminium composite panels (ACM) are routed, folded and welded to create box-form signage, building cladding panels with returns, and architectural facade detail. The ACM panel kit gives you the welder, fine nozzle and rod combination matched to the polyethylene core of standard ACM panels.
Signage manufacturing
Box-form retail signs, illuminated signs, lightbox housings, branded shopfront signs. The standard fabrication method for large flat-faced signage.
Building cladding
Architectural cladding panels with welded returns at edges and corners. Standard ACM brands include Alucobond, Reynobond and Etalbond.
Interior architectural panels
Lift cars, reception fit-outs, retail interior cladding. ACM gives a flat, painted-aluminium finish without the weight of solid aluminium.
The ACM box-form fabrication process
- Rout the panel using a V-groove or square-groove router bit, leaving the back aluminium skin intact.
- Fold the panel along the routed lines. The aluminium back skin acts as the hinge.
- Weld the corner joints with PE rod and a fine nozzle. The weld seals the core and bonds the joint.
- Trim and clean any excess rod from the corner with a sharp blade for a clean finish.
- Apply finishing details as required: drainage holes, fixings, mounting brackets.
Kit contents
| Component | Purpose |
|---|---|
| Hot-air welder | Typically a Triac with digital temperature control. Heat range needed for PE-HD welding (350-400°C). |
| Fine speed nozzle | Sized for the narrow corner joints in folded ACM panels. Smaller than general fabrication nozzles. |
| PE rod (HD) | Matches the PE core of standard ACM panels. Test on offcut to confirm bond with the specific brand of ACM. |
| Finishing roller | Small-profile roller for compressing the corner weld without damaging the aluminium skin. |
| Brass brush | Fine brush for cleaning the panel edge and core before welding. |
| Trimming blade | For removing excess rod from the corner after the weld cools. |
Fire-rated ACM
Post-Grenfell, fire-rated ACM (FR or A2 grade) is required for most commercial cladding work in New Zealand. Fire-rated cores are mineral-filled rather than pure PE and the welding behaviour differs. Always check the panel manufacturer's datasheet and confirm welding suitability before fabrication. Standard PE-core ACM remains common for signage and non-cladding applications.
Related guides
Frequently asked questions
What is ACM and why does it need welding?
ACM (Aluminium Composite Material) is a sandwich panel: two thin aluminium skins bonded to a polyethylene core. It's the standard cladding and signage material for commercial buildings, retail fronts and large signs. The PE core is welded when fabricating panel-to-panel joints, returns, and box-form signage where the core needs to be sealed and bonded.
Which rod do I use for ACM core welding?
PE rod — specifically PE-HD or PE-LD rod that matches the core polymer of the ACM panel. The major ACM brands (Alucobond, Reynobond, Etalbond) use similar PE cores so a generic PE-HD welding rod typically works. Always test on offcut first to confirm bond.
What's a typical ACM welding application?
Box-form signage: large commercial signs are fabricated from ACM by routing the panel, folding it into a box, and welding the corners. The weld seals the core, prevents water ingress, and stiffens the box. Building cladding panels with vertical or horizontal returns are made the same way.
Is ACM welding the same as regular PE welding?
The welding technique is the same hot-air method, but ACM-specific kits include finer nozzles for the small corner welds and a brass brush sized for cleaning the aluminium edge before welding. The aluminium reflects heat, so timing and air-flow management matter slightly more than welding bulk PE.
Are there fire-rated ACM cores I need to be aware of?
Yes. After international cladding-fire incidents, fire-rated ACM (with FR or A2 cores) is now required for many commercial cladding applications in NZ. Fire-rated cores are mineral-filled rather than pure PE and may not weld the same way as standard PE-core ACM. Check the panel datasheet and confirm welding suitability with the manufacturer before fabrication.
Need help choosing the right ACM panel kit?
Tell us about the job: the plastic you're working with, the wall thickness, and how often you'll use the tool. We'll recommend the right combination for the application.