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 winning line-up for complete and patented automation in the composite panel machining process is called the Integrated Work Cell and is part of the technology solutions, signed Muratori Machines.

The Integrated Work Cell has been designed and built to fully meet the specific needs of those who process composite panels and require advanced and innovative tools for crucial phases of the production cycle, such as loading, positioning on the CNC, machining and unloading of machined panels.

We refer to panels, often heavy and large, made of composite materials such as ACM (PECore or Mineral Core), solid aluminium, aluminium honeycomb panels, wood, HPL and fibre cement.

These are the panels that have to be taken from the pallet and positioned correctly on the machining centre, to be processed and then unloaded from the table for further processing.

How did we automate loading, positioning and unloading?
We have made this possible precisely by integrating three patented Muratori Machines technologies into the:

1. Alu Loader (patented): Loader – Positioner for composite panels with vacuum suction gripper arms
2. Alu Ranger: Machining Centre with Vertical Table for Machining Panels for Architectural Facade Fabrication 
3. Off Loader (patented): Automatic unloader of machined panels via vacuum table. 

What are the concrete benefits of this integrated automated system?

• The possibility of working in a continuous cycle, as the machining process is independent of loading and unloading operations
• Increased daily productivity, thanks to the efficiency generated by automation on the machines, which enables high work rates
• Cost reduction: need for only one operator to oversee the entire production cycle
• Increased efficiency: possibility of using resources for higher value-added activities, compared to loading and unloading operations
• Increased safety for the operators: automation prevents operator fatigue and there is no risk of panels accidentally falling.
• Smart Factory data integration and sharing (Industry 4.0 readiness)

The Integrated Work Cell, thanks to the technologies making it up, also makes it possible to solve both the problems of limited space, in the production area, and those of the necessary tipping of panels, in some cases, before they are loaded onto the Work Centre. How? Thanks to the automatic operations of the Alu Loader arms and vertical solutions. 

Find out how the Integrated Cell works, the specifications of the individual technologies, their patents and the specific advantages at the stage of the production cycle in which they are involved.

What do architectural façades, the transport industry, interior design projects and visual communication have in common?
Certainly, in all these sectors, there is a need to process the edges of composite panels, in different materials, to fulfil specific functions and meet precise technical and aesthetic requirements.

The ALU Bender automatic milling and bending machine is designed to meet these requirements precisely and with quality results.

This multifunctional machine is designed to be perfectly effective in panel edge processing, depending on the type of material and sector:

• ACM / ACP, PE Core, MINERAL Core, Solid Aluminium and solid Aluminium for Architecture, Interior Design, Visual Communication and the Transport Industry
• HPL for Ventilated Facades and Interior Design
• Honeycomb, Solid Aluminium, Solid Aluminium and Corrugated Core Aluminium for Ventilated Facades and Transport.
• Fibre cement for Ventilated Facades and Interior Design

At Muratori Machines, we design and manufacture machines and technologies for processing aluminium panels and composite materials. We work in an industrial environment and design and develop our products to facilitate the traditional production cycle of our customers, through innovative technologies that automate processes in the machining of composite materials.

We have been acquainted with this field of work for three generations and still have the desire to revolutionise traditional design and production paradigms, with a view to maximum ergonomics, practicality and ease of use. “Innovation” is a key word for us and we believe that patents are a confirmation of this. We have patented technical inventions that make the machining process better and more efficient through new technologies, and we also feel like innovators in disrupting the status quo, when we see and touch the concrete benefits our customers obtain when using Muratori Machines technologies.

Let’s get to the heart of some of the patents and see how they actually improve some of the operations in the machining of aluminium and composite panels.

#Patent – Device for loading flat elements onto a machine tool

The patented automatic Alu Loader is made for loading panels and positioning them on the CNC with the Alu Ranger Vertical Table. This is the machine with vacuum suction gripper arms, connected to the vacuum system of the machining centre.
The main advantages relate to the automatic loading of panels, without the need for operators, or manual tilting and, therefore, avoiding the risk of accidental panel falls.

#Patent – Vacuum worktop for a pantograph

#Patent – Device for handling workpieces in a machine tool

In the panel processing process, the handling of the machined panels is of paramount importance, perhaps as much as the machining itself, because accidental falls or tipping can damage the panels themselves or require the involvement of extra labour for low value-added activities. Automating unloading operations, on the other hand, guarantees precise handling that safeguards the panels, avoiding waste of material, time and resources.

How can panel unloading from the CNC be automated?
In order to make the unloading of CNC-machined panels automatic, at Muratori Machines we have developed and patented Off Loader, the automatic unloading system, connected to the Alu Ranger Vertical Table Machining Centre.

The Off Loader is equipped with a tilting vacuum table, covered with a breathable cloth, also patented, and is able to tilt until it covers the table top of the machining centre to pick up and hold the panels, and return to a horizontal position to unload the workpieces.

Off Loader performs the automatic unloading of panels in 4 steps:

1. The unloading table approaches and aligns with the Work Centre to pick up the panels
2. The vacuum table is pressed onto the workpieces, triggering the vacuum exchange of the table of the Machining Centre with the table of the Unloader
3. The unloading table moves away from the machining centre and back into a horizontal position, leaving the CNC ready to load and position the next panel via Alu Loader and Alu Feeder.
4. The operator operates the breathable belt, via foot pedal, to approach the panels and complete the unloading from the Off Loader.

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.