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According to extensive data from the decorative aluminum panel industry, the demand for double curved decorative aluminum panels has been steadily increasing every year. Aluminum panels with unique double-curved designs have thus become a popular choice for building decoration, highly favored by both contractors and designers.
So, why are double curved aluminum panels so popular?
First of all, double curved aluminum panels possess the key features of standard decorative aluminum panels, while also offering excellent adaptability to different curvature designs. This meets designers’ creative concepts and gives buildings a beautiful and distinctive appearance.
Next, let’s take a closer look at double curved decorative aluminum panels.
Double curved decorative aluminum panels, also called curved aluminum panels, are products with two curved surfaces. They are made from decorative aluminum sheets as the base material and undergo multiple processes, such as cutting, edge folding, bending, reinforced welding, surface polishing, and painting. Simply put, they are aluminum panels curved both horizontally and vertically.
1. Material Properties
① Meets the standard properties of decorative aluminum panels: lightweight, strong, dustproof, moistureproof, fire-resistant, corrosion and weather resistant, long-lasting, and resistant to UV and high wind loads.
② Surface finish and color can be customized, creating beautiful decorative effects.
③ Diverse shapes clearly display the curves of the design.
④ Convenient structural design and easy installation.
⑤ Easy to repair and modify, allowing design adjustments.
⑥ Low thermal stress; can be connected with other materials like glass, metal, and stone using flexible materials to reduce stress from temperature changes.
2. Product Types
Double curved aluminum panels come in various shapes and curvatures, such as spherical, hemispherical, bi-directional twist, and single curve.
Product sizes:
Standard sheet sizes: 600×1200 mm, 600×1500 mm, 1000×2000 mm. Maximum sheet size: 1200×2400 mm (larger sizes can be joined). Standard thickness: 2.0–3.0 mm. Maximum thickness: 5.0 mm.
3. Manufacturing Process and Key Points in Installation
Double curved decorative aluminum panels are prefabricated and must be produced in a factory before being assembled on site. This requires high precision from the factory.
1. Manufacturing process
The main methods for forming double curved aluminum panels include film mold forming, multi-point pressing, metal mold stamping, 3D flexible roll forming, and on-site forming.
① Film mold forming
This is the most common method. A film mold is created according to the design. The aluminum sheet is pressed onto the mold using rubber and manually tapped with a hammer to fit. Excess edges are trimmed, producing the curved panel according to the design.
Molds are usually made from wood, plastic, or steel. Advantages: suitable for mass production, high speed, high precision. Disadvantages: high mold cost, not suitable for small-scale or multi-type production.
② Multi-point pressing
The mold consists of multiple adjustable points and is reusable. The product has low deviation but high cost, suitable for small-scale production.
③ Metal mold stamping
The metal mold has upper and lower parts. Hydraulic stamping is performed in one press. Suitable for mass production, but not for small quantities of special-shaped pieces.
④ 3D flexible roll forming
Rolls can curve as needed. The sheet to be formed is clamped between the rolls, which rotate simultaneously, deforming the panel both vertically and horizontally. Suitable for complex curved aluminum sheets but expensive and costly to maintain.
⑤ On-site forming
Used for panels with large radii. Software calculates panel hanging positions. Steel frames and curved pipes serve as a "ruler" to adjust and fix panels, reducing costs but requiring high expertise.
2. Key points in installation
Installing double curved aluminum panels is relatively easy but requires expert handling at every step to achieve the intended design.
Start by creating a 3D model and calculating the size and position of the panels in the factory. Then install the prefabricated panels onto the steel framework on site.
