Architects and designers are increasingly pushing the boundaries of design to create complex and compelling surfaces in projects.
Whether it is hospitality interiors, offices or the yacht industry, there is a desire for original design and beautiful aesthetics, with the natural look of wood in demand.
Some demanding design applications aren’t always easy or possible using all wood materials, but there are still capabilities for wood products to play a role.
Enter Danzer’s 3D Veneer – a real wood veneer product with the capabilities to be formed into complex shapes without cracking. The material has been used in many applications globally – with a variety of substrate materials, including moulded plywood parts – such as chair shells, back rests, elements for furniture fronts, accessories, and car interior trim.
Non-wood substrates have also been used in recent years, and those applications are growing. It is giving good possibilities for a real wood surface even when the substrate material is man-made, such as metal or plastic.
The unique 3D veneer was developed to mould veneers three-dimensionally without cracking to achieve stable moulds – for example for the furniture and automotive industries – that are resistant to breakage or bending. Both the structure of the wood and texture of the veneer are unchanged in the process.
WIDER APPLICATIONS
Every single gram counts when it comes to deck furniture for yachts and panelling for vehicles such as caravans. This is where a fascinating combination of 3D wood veneer and maridur PU – a thermally and mechanically mouldable material from OBOWerke GmbH – has been created.
OBO’s roots back in 1869 were as a sawmill, moving into technical plywood for the aviation industry in the 1930s and impregnated compressed wood in the 1970s, before moving into PU boards.
In co-operation with Curve Works BV, the areas of application of the material have now been extended specifically to large components and exterior elements such as staircase covering, cabinets and doors in shapes including circles, waves and organic shapes.
Thus, the solution creates a very lightweight, flexible product that can be thermoformed in complex curves and radii as required, with a high-quality aesthetic natural surface.
Seamless wooden surfaces add a touch of refinement to the sophisticated geometries, even in large formats.
Danzer has held a patent for 3D veneers since 2008. To do this, the veneer is processed in advance so that it wraps around the component and fits seamlessly.
“We cut the material into thin strips 1.2mm wide to achieve this effect,” explained Thomas Wenk, master for wood technology at Danzer.
“These strips have threads bonded on the back which holds them loosely together. This constructs a grid of around 10mm, which yields easily and can be formed in different shapes.”
This way, Danzer can create parts for chairs for example, and can laminate interior panelling in car passenger compartments, as well as elements in yachts and aircrafts.
OUTDOOR AND WET AREAS APPLICATIONS
Of course, demanding outdoor applications in wet areas can be challenging for surfaces.
In 2018, and in collaboration with Danzer, OBO succeeded for the first time in thermally moulding maridur panels in their raw state and coating them with a weatherresistant 3D veneer.
For architects and designers of yachts and luxury vehicles this opened up completely new design possibilities for both interior and exterior applications.
Since the end of 2023, however, OBO has been thinking even bigger: the manufacturer has also brought Dutch moulding experts Curve Works BV on board. It has the technical capabilities to create large-format components quickly and cost-effectively from maridur by means of thermal forming.
THERMAL MOULDING AND LIGHTWEIGHT CONSTRUCTION
The new co-operation partner faced the challenge to find a high-quality processing method for the shortest possible production time.
“Cost-effectiveness can only be achieved here if a large number of components can be thermoformed in a single day,” said François Geuskens, Curve Works’ managing director.
The large-format components also benefit from the potential for sandwich construction: different densities between 80 and 1,600kg/m3 can be used in a single workpiece. For example, a lightweight core can be combined with a higher outer density material. This way weight can be saved while a high-class surface with high stability and resistance are combined.
This is particularly suited to larger deck furniture on yachts.
For further upgrading, the part – irrespective of size – is laminated with Danzer’s patented 3D veneer after cooling. “We use various vacuum techniques for this,” said Mr Wenk.
“The final result is a seamless veneer surface, even on curved, complex and organic shapes. The material can still move as the work progresses, so the component should not be laminated right up to the outer edges. As soon as the 3D precious wood surface is bonded, it becomes a rigid workpiece that cannot move. However, it can still be milled if required.”
Curve Works, OBO and Danzer all see great future potential for the solution.
