Warwick shines a light on the future of MDF

Laser technology is able to create quality finishes on low-cost materials. TiC looks at a research project that promises to light up the dreary surface of MDF.

PINK OAK or blue mahogany finishes might become possible after researchers developed laser treatment technology to transform MDF to resemble other timbers.

The treatment can mimic the grain of other timbers onto the surface of low cost MDF and is currently under development by the WMG at the University of Warwick.

Researcher Dr Ken Young tells TiC there is a commercial push to using MDF in the place of other traditional timber products and manufacturers like the material because it is versatile, easy to work with and inexpensive.

Although it takes knocks from environmentalists for containing resins such as urea formaldehyde, Dr Young says MDF has good environmental credentials as it can be made from waste products such as softwood fibres.

“The beauty of MDF is it’s made out of waste materials such as sawmill waste and recycled timber,” he says. “A lot of people don’t think it’s that environmentally friendly, but it’s quite a green product really.”

However, MDF presents a conflict of interest between manufacturers and their customers. Much as the product’s versatility is a hit with manufacturers, it lacks the aesthetic appeal that traditional timbers can add to the finished project.

“The manufacturers want MDF because it’s predictable and doesn’t split, but the finish isn’t acceptable to the end customer,” Dr Young says. “It looks rather dull in its natural state and because of the finish, you find the customer usually wants wood. Until now there’s been no other way to brighten it up than to paint it.”

Light at the end of the tunnel?
The WMG became involved in the project to develop laser treatments for MDF after the Furniture Industry Research Association (Fira) contacted the organisation to find a solution to the problem of MDF’s appearance. The group is also working with Trada to develop the technology and the project is part-funded by the Department for Business, Enterprise and Regulatory Reform.

“Fira approached us because they were looking for someone who understood the laser technology,” says Dr Young. “We looked at it and thought it had potential. We’ve so far made samples, tested them and modified the plant.”

Although the WMG has yet to develop its Lasercoat technology into commercial applications, it has developed a sample door for Howarth (Timber) Windows and Doors. Other partners on the project include panel maker Norbord, paint and powder equipment supplier Exel Industrial, floor finishes maker Granwax and coatings producer Sonneborn and Rieck.

Young says the technology is very hardwearing and can be used for flooring and other applications where cost and appearance are of equal importance.

Howarth factory manager Mick Toner says the company wants to explore the potential of MDF to produce energy efficient doors. “We would love to use it for the glazing beads in double glazing but customers do not like the look of raw MDF,” he says. “It is an ideal material for providing the thermal insulation required for modern doors. Our customers are increasingly using translucent coatings on their doors, which are not aesthetically pleasing on MDF panels. The Lasercoat technology cuts through this problem, providing an attractive surface for the MDF, no matter what the coating used.”

Etching to succeed
The WMG has developed two processes for creating different finishes on MDF: etching and powder coating.

“They are two completely different and complimentary processes; it depends on what effect you want,” says Dr Young. “You can get quite different effects with powder coating, but just one effect with etching.”

He says Lasercoat can put any wood grain effect onto the surface of MDF, such as mahogany, birch, oak or pine. The technology works by scanning the pattern and converting it into a bitmap. The laser is then programmed to transfer it onto the MDF, through either etching or powder coating.

The WMG uses a standard powder coating procedure to create finishes on MDF.

The coating is applied to the surface of the MDF and, rather than curing the powder, it is selectively sintered. The unsintered powder can then be glowed off.

Dr Young explains that a variety of effects can be obtained through the procedure, such as creating different colours. “If you start with a yellow coating, it’s possible that you can modify the powder and turn it brown just by heating it,” he says.

However, he adds, the technology goes further than just altering colours. “There are a lot of possibilities,” Dr Young says. “As well as putting a grain pattern on it you can put a logo or greyscale image of someone’s face. You can do any picture that you want, although it might not have a great quality of colour.”

Dr Young says Lasercoat can create effects far beyond those of the designer’s traditional palate. “You can produce timber that doesn’t exist,” he says. “You can use very strong colours; blue walnut of pink oak. All these are possible. Some of the effects that we have obtained so far are fantastic.”

The technology has potential for companies working in the refurbishment and fitout sectors in order for contractors to create unique effects for their clients.

Warwick makes good
The WMG has recently invested in plant to help with further research.

“We’ve just bought a low powered laser from China, which cost £2,500,” he says. “It’s used for small samples.”

Despite the interest from Howarth, Lasercoat is still in its developmental phase and there are not yet any commercial applications for the technology. However, Dr Young says the WMG is gearing up to unlock its industrial potentials.

“The next few months of the project are about how we can put it on a commercial scale, the cost of the machinery and what the machinery would look like,” he says. “Even if none of the current partners want to take it forward, there are a lot of other companies that have showed some interest.”

Whether Lasercoat does resolve the conflict of interests between the low cost and the unattractiveness of MDF and create a desirable finish will be up to the customer to judge. However, the next phase for its progression will be to attract the interest of manufacturers and designers and to develop production on a commercial scale. Hopefully, high quality laser-produced finishes on this inexpensive material won’t be light years away.