3D LIGHTING DESIGN Processing of ETTLIN LUX fabrics www.lichtstrukturen.de
contents basics 3 Cutting 4 Scissors Knife Rotary Cutter Band saw Ultrasonic cutting Laser cutting Sewing Workplace layout Open cutting edges Kanten versäubern Ziernähte French seam Keder annähen 11 Joining 18 Ultrasonic welding Ultrasonic bonding Bonding on metal / plastics Bonding with iron-on nonwovens Press studs Velcro tape Clamping PVC piping Silicone piping Clamping profile Cord edge profile Stapling 26 Embedding in glass / acrylic glass Deforming 32 Reducing of buckles 36 Cleaning and removing of fingerprints 37 2
Basics ETTLIN LUX fabrics are sensitive to buckles They have a front and a back side (side of weft and warp): the back of the fabric can be recognized because of the structured surface and the black warp threads protruding from the surface The lighting effect develops along the black ribs ( direction of effect ) ETTLIN LUX Miracle fabrics are sensitive to grease spots, like fingerprints Cleaning is possible In warp and weft direction, the fabrics have almost no elongation Diagonally, they be deformed Punctual pressure must be avoided 3
3D LICHTDESIGN - cutting - 4
Scissors ETTLIN LUX fabrics can be cut with scissors. A fixation of the cutting edges is not necessary In opposite direction of the lighting effect a guide for cutting is necessary to achieve a straight cut In direction of the lighting effect it can be orientated towards the black warp threads 5 Cutting of ETTLIN LUX fabrics with scissors
Knife ETTLIN LUX fabrics can be cut with a knife. The cutting edges will remain open. An fixation of the cutting edges is not necessary A guide for cutting is necessary to achieve a straight cut 6 Cutting of ETTLIN LUX fabric with knife and guide
Rotary cutter ETTLIN LUX fabrics can be cut with a rotary cutter. The cutting edges will remain open. An fixation of the cutting edges is not necessary A guide for cutting is necessary to achieve a straight cut Advice: the use of a rotary cutter achieves the best results. 7 Cutting of ETTLIN LUX fabrics with a rotary cutter
Band saw Rolled ETTLIN LUX fabrics can be cut with a band saw.. It is important to consider the following settings: Slow sawing Use of a smooth, very sharp and not serrated saw blade Use of as little pressure as possible (lowest adjustment) If necessary, the use of bubble wrap to protect the fabric against pressure marks 8 Cutting of rolled ETTLIN LUX fabrics with a band saw
Ultrasonic cutting Ultrasonic cutting is possible by using a hand unit (stationary sonotrode) or by using an ultrasonic welding machine (stationary or rolling sonotrode). Fixation of cutting edges an cutting in one step 9 Cutting with ultrasonic hand unit
Laser cutting ETTLIN LUX fabrics can be cut with laser. Fixation of cutting edges an cutting in one step ETTLIN LUX fabrics are eurolaser certified 10 ETTLIN LUX Decolux and Mood fabrics, cut to size with laser
3D LICHTDESIGN - sewing - 11
Workplace layout Workplace layout and material feed: Working on a sufficent large workspace is recommended (to avoid buckles and wrinkles) Sewing machines should be integrated into large workspaces If a large quantity is fed to the sewing machine, the fabric should be processed when it is rolled up Machine setting - Recommendation for simple closing seam and lockstitch seam: Sewing machine with top, needle and alternating upper foot feed Teflon presser foot (to avoid pressure marks) Fine needle for non-visible needle holes (adjusted to thread thickness) Stitch length (4 stitches / cm) 12
Sewing: Open cutting edges ETTLIN LUX fabrics can be sewed. For this, a simple closing seam can be used (double chain stitch). Cutting edges remain open For closing seams we recommend the use of a polyester yarn, like Tera 80 of Gütermann Needle size NM 70-90 13 Closing seam on ETTLIN LUX Deolux fabric with Gütermann Tera 80
Neatening the edges (open cutting edges) Open cutting edges can be neatened by using a 3 Faden Überwendlichnaht to avoid fraying at the edges For overlock seams, we recommend the use of a polyester yarn liketera 80 of Gütermann 14 Neatendes edges of ETTLIN LUX Mood 1352, 1368, ETTLIN LUX Decolux 2105, 2507 (top-down) with Gütermann Tera 80
Decorative seams For decoartive seams we recommend the ude of a polyester yarn like Tera 60 of Gütermann Needle thickness NM 90-100 15 Decoartive seam on ETTLIN LUX Deolux fabric, made with Gütermann Tera 60
Sewing French seam Advantages: Cutting edges are not visible Higher resistance Stick up backwards directly (do not disturb the light effect) right face = visible side Advice: Machine with top feed and lower feed Teflon presser foot (to avoid pressure marks) Fine needle (Nm 70-75), for non-visible needle holes Stitch length 2,5 (4 stitches / cm) Important: Seam parallel to direction of effect: it must be sewed straight (an oblique seam will be visible when folding back the two fabric layers)!!! Sewing yarn: depending on application Transparent monofilament yarn unremarkable PES, PTFE yarn higher resistance 16 French seam on ETTLIN LUX Mood fabric 1368
Sewing on pipings Pipings, e.g. made of silicone, can be sewn on by the use of a double lockstitch. Recommendation: Fixation with two seams Folding-in the fabric Use of a polyester yarn, liketera 60 of Gütermann, for high strength 17 Silicone piping, sewn on ETTLIN LUX Miracle fabric
3D LICHTDESIGN - joining - 18
Ultrasonic welding First tests with ultrasonic welding have been successful. Possible by using a hand unit (stationary sonotrode) or by using an ultrasonic welding machine (rolling sonotrode) The setting of frequency and pressure must be set so that the seam doesn t get fragile Fixation of cutting edges and cutting in one step Assembling of two fabric layers use of a flat sonotrode Important: The two fabric directions behave differently in welding: weld seam parallel to direction of effect: cutting, fixating and joining of two fabric layers in one step is possible weld seam perpendicular to direction of effect: only cutting is possible Only to cut and join together two fabric layers. Not for fixing other materials, especially when the joint is under high strains (like piping)! ) 19 ETTLIN LUX fabric layers, joined with ultrasonic welding (coined sonotrode)
Ultrasonic bonding For the bonding of two fabric layers. Inserting of the overlapping fabric layers into the guidance device Positioning of the adhesive tape between them Use of a hot melt tape that is as narrow as possible The adhesive tape must be highly transparent after processing 20 ETTLIN LUX fabric layers, joined with ultrasonic bonding
Bonding on plastics / metal ETTLIN LUX fabrics can be bonded around panels or frames made of plastics or metal by using a self-adhesive tape. Recommendation: transparent acrylate selfadhesive tape (z.b. VHB by 3M, 4965 by tesa, ACXplus 7054 by tesa ) For higher strength: Tesafix 62932 in black Suitable for exterior use Tesafix 62932 (tesa ) 4965 (tesa ) ACXplus 7054 (tesa ) VHB (3M ) 21 Bonding of ETTLIN LUX Miracle fabric on PMMA with Tesafix 62932 (above) and ACXplus 7054
Instructions The self-adhesive tape must be fixed circumferential on the panel/frame. With a squeegee, the tape has to be pressed on without any bubbles. The protective foil on the upper side should not be removed yet! The ETTLIN LUX fabric has to be rolled up on the panel / frame with the side of the warp this is the side that will be stucked on The fabric has to be adjusted parallelly to the frame orientation along the black warp threads The bonding has to be started at the short side: At first, the protective foil must be removed, then the fabric must be pressed on softly to correct, if necessary The protective foil must be removed on the longer side step by step. It is necessary to work from one side to another (left and right) and to remove folds / surplus fabric. Afterwards, the fabric must be pressed into the self-adhesive tape softly. the fabric has to be stretched evenly in every direction If this is the case, the fabric must be pressed firmly in into the self-adhesive tape with a squeegee
Bonding with iron-on nonwovens Iron-on nonwovens can be used to join ETTLIN LUX fabric layers. Use of a interlining that is as narrow as possible The durability of the joint is limited (depending on stress) 23 Bonding of two ETTLIN LUX Mood fabric layers with iron-on nonwoven
Press studs ETTLIN LUX fabrics can be assembled point by point with press studs. For 2 fabric layers A reinforcement material, like an iron-on nonwoven, has to be fixed under the press studs to reach more stability Wrinkles can appear while opening and closing Loose connection Important: not suitable for full-surface stretched fabrics 24 ETTLIN LUX Mood fabric with press stud
Velcro tape A self-adhesive velcro tape can be used to join ETTLIN LUX fabrics. Installation with taping Sewing reaches higher resistance Surplus, the fabric can be fixed and clamped on a frame. Fixation of the self-adhesive part on the frame Sewing of the other part on the fabric Important: the fabrics have to be cut straight 25 ETTLIN LUX Mood fabric, fixed on a frame with the use of a velcro tape
3D LICHTDESIGN - clamping - 26
Clamping PVC piping ETTLIN LUX fabrics can be clamped into special profiles with PVC pipings. The piping must be sewed on the fabric High frequency welding is not possible Advantage: quick exchange of different fabrics onto one frame is possible Important: ETTLIN LUX fabrics have no elongation. The piping has to be sewn on exactly 27 Sewn-on PVC piping
clamping silicone piping ETTLIN LUX fabrics can be clamped into special profiles with silicone pipings. Fixation with double lock stitch Advantage: quick exchange of different fabrics onto one frame is possible Important: ETTLIN LUX fabrics have no elongation. The piping has to be sewn on exactly 28 ETTLIN LUX fabric with sewn-on silicone piping
clamping clamping profile Ettlin LUX fabrics can be clamped into special profiles with the use of a spatula. The fabric has to be clamped in with an angle of 90 Only profiles with rubber lip should be used (give stability an do not damage the fabric) Corrections by extracting the fabric is possible Serrated profiles should not be used! Profiles in which the fabric has to be brought in with an angle should not be used! 29 ETTLIN LUX fabric fixed in a clamping profile
clamping cord-edge profile Ettlin LUX fabrics can be clamped into special profiles with a plastic cord edge and the use of a special tool. Firm and stable fixation The frame can be sized individually Non-visible fixation from the visible face of the fabric 30 Clamped-in ETTLIN LUX Mood fabric
clamping stapling ETTLIN LUX fabrics can be clamped by stapling the fabric onto different materials, like wood. Advantage: quick and less expensive clamping method Important: staples should be appliqued closely and evenly. Otherwise there will be a risk of undulated surface because of pressure differences 31 ETTLIN LUX Decolux fabric, fixed on a wooden frame with stapling
3D LICHTDESIGN - embedding and deforming- 32
Embedding in glass / acrylic glass ETTLIN LUX Mood und Decolux fabrics can be bedded into glass. The lamination has been successfully accomplished by the vacuum bag process. See document: ETTLIN LUX laminated glass: processing istructions / ways of embedding. The embedding of ETTLIN LUX Mood und Decolux fabrics in acrylic glass is also possible (ETTLIN LUX SmartPanel). 33 ETTLIN LUX SmartGlas
deforming When ETTLIN LUX fabrics are embedded in acylic glass, thermal deformation is possible afterwards. Only possible in one direction The fabrics cannot or only limited be thermoformed. 34 ETTLIN LUX Mood fabric in acrylic glass and deformed
3D LICHTDESIGN - reducing of buckles - - cleaning - 35
reducing of buckles Soft buckles and wrinkles can be reduced with the use of hot air or hot steam. See document: cleaning and removing of wrinkles on ETTLIN LUX fabrics 36 Removing of wrinkles on ETTLIN LUX Decolux fabric with the use of a steam generator
cleaning and removing of fingerprints ETTLIN LUX Miracle fabrics are sensible to grease spots, like fingerprints. These can be removed. See document: cleaning and removing of wrinkles on ETTLIN LUX Miracle fabrics The cleaning of ETTLIN LUX fabrics of dust and stains is possible. See document: cleaning of ETTLIN LUX fabrics 37 Fingerprints on ETTLIN LUX Miracle fabric