Alu Ranger fabricates the edges by proprietary tools obtaining the hemming of the edge. Hemming is obtained by a mechanical bending of the main alu skin of the ACM panels. Bending can be done in curves too thanks to the high CNC performance of Alu Ranger family of machines.

What is hemming on ACM good for?
Every time the edge is exposed and requires to be hidden for protection or for aesthetical reasons.

Wish to use ACM in interiors but the edge sucks?
Using Alu Bender for straight bending/hemming or Alu Ranger for straight and curved bending/hemming you can cover all your edges and surprise your customers.

Discover how to do your best job by using Muratori Machines patented technologies for composite panels.

Composite panels for architectural façades, interior design, industrial application or transport industry, must meet precise technical requirements, as well as ensure excellent performance and weather resistance. But aesthetics also plays an important role.

In fact, the same panels not only add value to building envelopes and transport interiors, but are also used in interior design and visual communication, areas in which aesthetics is fundamental, if not the very essence of the project. Hence the need to make the edge of composite panels beautiful as well.

What is the most effective way to machine and make the edge of panels beautiful?
Definitely by using a unique technology on the market for continuous edge milling and bending, such as Alu Bender.

Yes, to meet the technical requirements of durability and resistance to bad weather conditions, and to combine them with aesthetic ones, at Muratori Machines we designed and built Alu Bender: a multifunctional machine for processing the edge of composite panels used in architecture, transport, interior design and visual communication.

Unique technology on the market, made for automatic continuous edge milling and bending

The first special feature of the Alu Bender is that it is unique on the market for automatic continuous edge milling and bending.

The Alu Bender is able to work with the highest precision:

• double bending
• multiple machining on aluminium honeycomb
• edge finishing of fibre cement and HPL panels
• Multiple edge hemming ACM, Core PE and Core Mineral

Panels, even large ones, are machined and bent very accurately, supported at the infeed and outfeed in a precise and safe way, both for the panel and the operator.

Here are 5 reasons to choose Alu Bender for edge machining of composite panels:

1. in the case of ACM panels, it allows the edge to be crimped, possibly also with external double folding
2. in the case of aluminium honeycomb panels, it performs a perfect bending radius on the edge, hiding the core from view and improving weather resistance
3. during edge milling of HPL and fibre cement panels, it eliminates bevels and allows edges to be chamfered
4. in the case of fibre cement panels, it also applies LUKO® liquid, within the same processing cycle
5. in the case of aluminium honeycomb panels, it automatically performs continuous flattening, for laminated or ‘H’ profile assembly

Alu Bender is unique, but it is not the only Muratori Machines technology for edge bending. In fact, Edge Bending machines also include the Alu Doubler series, which consists of two machines, Alu Doubler F and Alu Doubler P. 

Alu Doubler F is designed for cutting one of the two skins of aluminium honeycomb panels and VGroove one or two lines for single or double bending.

Alu Doubler P is designed to bend the main skin of aluminium honeycomb panels previously machined on Alu Doubler F or CNC Alu Ranger.

Looking for a single partner for composite panel machining?

Contact us to find out how we can improve your production process.

We are talking about ACM panels, aluminium honeycomb (AHC), but also HPL panels, fibre cement. Just how many times have we thought about how to hide the edges of these panels or how to face them? Today we finally have the right answer to solve this problem. Thanks to Alu Bender it is possible to process the edges of panels for architectural façades, interior design, the transport industry and visual communication. Yes, but how?

It is a fact: the edges of machined panels need to be improved in order to leave them “exposed”. Depending on the material in question and the intended use of the machined panel, the edge of the panel can be covered or a finish can be applied over it, adopting manual solutions. What do we choose and, more importantly, on the basis of what do we choose?

Think about the world of ventilated façades or the world of transport: what is the common denominator for panels exposed outdoors?
Aluminium or composite panels are necessarily exposed to the weather or natural elements, which can cause them to deteriorate.
Therefore, panels made of ACM/ACP, Pe Core, Mineral Core, Aluminium Honeycomb, Aluminium Corrugated Core, but also those made of solid aluminium, HPL or Fibre cement need to be processed in a specific way, according to the material characteristics and application context.
We started from here to design and manufacture Alu Bender, the multifunctional automatic bending machine for machining panel edges.

Why Multifunctional?
Alu Bender is multifunctional because it improves panel edges through
 – hemming
 – folding
 – crushing
 – finishing
 – edge protection

considering the characteristics of each material and ensuring industrial productivity.

Let’s go into detail about materials, requirements and edge processing.

Edge processing of ACM / ACP panels (PE CORE and MINERAL CORE)
In the fields of Architecture, Transport, Interior Design or Visual Communication, “non-box” panels are processed as rectangles with sharp-edged edges, exposed to the elements and unattractive to the eye. Edge protection expands the use of panels into areas usually reserved for other materials. This is where Alu Bender mills the panel and bends the exposed skin, covering the core and protecting it from weathering. The edge bending radius is perfect for all types of aluminium composite panel.

Edge processing of aluminium honeycomb panels for the ventilated façade and transport sector
By milling and bending one of the two skins, Alu Bender improves the protection of the core from the weather and covers it from view. The bending radius at the edge is perfect for all types of aluminium honeycomb panels. In the transport industry, aluminium honeycomb panels are coupled by means of aluminium profiles to make partition walls. Flattening along the edges allows the panels to be inserted into ‘H’ profiles or assembled in pairs. Normally the flattening process is performed by presses that have limitations in the length of the panel to be processed.

What is the added value of Alu Bender here? The Alu Bender automatically performs continuous crushing by working on any length.

Edge processing of solid aluminium panels for ventilated façades
In this case, Alu Bender mills the panel and bends the pre-painted skin, covering the edge from view and weathering. The bending radius on the edge is perfect for all types of solid aluminium panel.

Edge processing of HPL panels, for ventilated facades, but also for interior design
Machining this material can result in obvious blade marks, chipping, edge dullness and sharp edges. The use of a machining centre improves the finish but causes a loss of productivity and high labour time costs. Alu Bender allows fast and perfect edge finishing with reduced machining costs and therefore without the use of a CNC. In a single machining cycle, it is possible to obtain a perfect finish of the edge surface and to smooth its edges.

Edge processing of fibre cement panels, for ventilated façades, but also for interior design.
Cutting with a circular saw requires further processing to chamfer the edges of the edge to prevent brittleness. The edge requires further manual treatment against moisture using a special liquid. In this case, Alu Bender chamfers both edges of the edge and automatically applies LUKO® liquid or similar in a single processing cycle.

Edge processing of corrugated aluminium core panels for ventilated facades and transport.
Corrugated or profiled aluminium core may not be treated for corrosion protection. Exposure to weathering can cause it to deteriorate. Here again, by milling and bending one of the two skins Alu Bender improves the core’s protection from the elements and covers it from view. The bending radius is perfect for all types of panels with corrugated or profiled aluminium cores.

What can you do specifically?
Read more here

The optimal machining of ACM, ACP, solid aluminium, HPL and fibre cement, or wood panels, especially large and, in the latter case, particularly heavy panels, can be done on a CNC with Vertical Table, benefiting from multiple advantages.

So is there a CNC with a Vertical Table?
Yes, at Muratori Machines we are focused on innovation and quality to find those solutions that disrupt the status quo and revolutionise design and production paradigms in the world of composite panel machining. With this in mind, innovation finds its full expression in the verticality of the worktable of the Alu Ranger CNCs, made to machine panels, often large and heavy, in ACM/ACP, HPL, solid aluminium, wood, HPL and fibre cement, aluminium honeycomb panels and corrugated or profiled aluminium core panels.

The Horizontal Table is undoubtedly very popular, but it has certain limitations that affect daily work, in terms of efficiency, productivity and ergonomics, and therefore also costs.

After analysing the problems faced by those who work with these panels, in Architecture, Interior Design, transport Industry or Visual Communication, we designed and built the Alu Ranger – our CNC with Vertical Table – a technological solution that ensures precision, quality, cleanliness, greater efficiency in production, and safety at work.

Furthermore, it is essential to consider specific aspects such as the space occupied by the machines in production, the number of resources employed, and the condition of the work surface, which, if poorly cleaned, risks damaging the panels.

Do our CNCs with Vertical Table take these aspects into account?
It is precisely because of the verticality of the table that the Alu Ranger CNCs respond precisely to the actual needs of those working with composite panels, offering a great competitive edge, in terms of:

• large space savings: -60% occupied floor space compared to a horizontal machining centre
• efficiency, precision and machining quality: the solidity of the base and the flatness of the vertical structure ensure greater vibration absorption, hence less notching of the cut, as well as longer machine and tool life
• cleanliness of the work table: the shavings produced during machining and not extracted thanks to the inclination of the table, fall and leave the surfaces perfectly clean, preserving the integrity of the panels
• reduction of waste and errors: thanks to the Cad-CAM software, optimised by 4 hands with the software house and our customers, the machine is able to generate efficiencies in panel machining, through the automatic correction of errors on drawings, for example, in order to improve the cutting process 
• greater control of the process from a single point the vertical table allows the operator to have full view of the machining process, hence control over the work progress
• ergonomics and safety: verticality makes work more ergonomic and reduces the risk to operators, guaranteed by the side guards and photoelectric cells equipping the CNC

Edge enhancement is certainly another important aspect to consider for anyone machining ACM (PE and mineral core), aluminium honeycomb (AHP), aluminium corrugated core, HPL or fibre cement panels. Typically, these processes require manual working, thus with inefficient processes and no guarantee of repeatable quality.

What are the machining operations that enhance panel edging?

• Milling and bending for aluminium composites (ACM, AHP), to hide the core.
• Edge milling and bottom top chamfering of HPL and fibre cement panels, in order to eliminate imperfections and circular saw cut jaggedness.
• Edge milling and double folding of aluminium honeycomb (AHC) panels, for joining the two skins mechanically.

So, let look at this operation more closely. Machines, such as spindle moulders with a driver, or CNCs combined with an operator’s manual skills, can be used for the bending operation. However, such processing is costly and offers no guaranteed quality. Let’s look at individual materials to better understand what the specific needs are and then evaluate the most efficient solutions with repeatable quality.

ACM, AHP, AHC panels:
The customer can mill the panels by freeing the skin to be bent via CNC. The problem is the manual bending of the freed skin, keeping the bending radius constant at 2 mm.

Composite material panel handling activities also involve the loading and positioning of the panel itself on the Machining Centre which are undoubtedly of key importance for customers who are looking to improve their machining process.

How can loading operations be performed?
There are some precautions to consider, both regarding personnel and to panel positioning. In fact, loading the panel from a pallet onto a horizontal machining centre requires two or more operators, and the ACM panel must be flipped, as it is generally placed on a pallet with the “side to be worked” facing downwards. Furthermore, we must consider that in the case of HPL and fibre cement panels, the load in question is extremely heavy for the operators involved.

Is there a more efficient solution that safeguards operators?
In this scenario, it became mandatory for us at Muratori Machines to think of and design a more efficient solution, in terms of time and resources involved, for composite panel loading operations. We created, developed and patented an automatic system – Alu Loader – that picks up the panel from pallets by lifting it and placing it back on its own structure.

How does this overcome operator and correct panel positioning issues?
The Alu Loader is designed to take the panel from the pallet and flip it so that the “side to be worked” automatically faces the Alu Ranger CNC tools. The pneumatic arms of this automatic loading system are able to lift heavy weights and handle them smoothly. Once the Alu Loader has lifted the panel and placed it in the correct position, it is picked up by the Alu Feeder, which is a system connected to the Alu Ranger‘s crossbeam, equipped with suction cups, and which enables the panel to be moved into position for machining on the Alu Ranger.