This method uses a heat press machine and an aluminum mold to make plastic board, which is then formed into perforated board.
Heat press machine…commercially available heat press machine for iron-on printing. The one I am using has a 350x350(mm) heat surface.
Aluminum frame…I found a supplier online that sells and processes aluminum sheet metal and placed an order. 230x300x4(mm) rectangular frame with 5mm radius on the corners. This aluminum frame is sandwiched between two aluminum sheets (2 mm) and pressed.
Steps 1 and 2 are based on "Zero Plastic Australia's Sheet Machine" by Zero Plastic Australia. Please refer to this one too!
Aluminum sheet - Teflon sheet - Milled plastic & aluminum frame - Teflon sheet - Aluminum sheet
The materials are set in the heat press machine in a sandwich condition like the above. At this time, it is recommended to spray the aluminum frame thoroughly with silicone spray. For this aluminum frame, roughly 350-400g of milled plastic is required.
After setting the materials and closing the heat press, heat the machine at 180°C for 30-40 minutes. During this time, keep increasing the pressure of the heat press to the maximum. Apply heat and pressure evenly, rotating and flipping the whole aluminum sandwich sheet during the process.
Then turn off the press and allow the plastic to cool and harden in place while keeping the pressure applied. After at least four hours, and ideally overnight, the plastic should be nice and flat.
Once the plastic has cooled and hardened, peel it off from the frame, cut off the unnecessary parts with scissors, and your plastic sheet is ready!
Prepare a peg board for guides. I used "Design Board 30cm x 20cm (natural x white): 110 yen" from Daiso. The size of the holes is 5 mm and the hole spacing is 25 mm.
Stack the peg board on the plastic board and fix it with clamps to prevent it from moving. Aim at the center of the perforated board and drill guide holes 2 mm in diameter.
After the guide holes are drilled, remove the perforated board and fix only the plastic board to the workbench. Replace the drill with one of 5 mm diameter and drill the actual holes as per the guide holes.
After all holes are drilled, remove the remaining plastic debris around the holes. If there are too many burrs on the surface, use an orbit sander to finish the surface. If you apply up to about #2000, the color of the plastic will be bright.
And voila! The plastic pegboard is now complete!
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