Here we have placed our hotbending machine on the joint that is to be bent.
We used our laser-cutted acrylic angeles to bend the polycarbonate-sheet in to the right angle.
The last bend is a round corner, the radius is 200mm. We knew it would be very hard to bend it.
We heated like 100mm of the polycarbonate with both hot air gun and the heat bending machine. We heated the area for at least 20 minutes, it wouldn’t bend.
Our heating machine turned out to be far more superior to the hot air gun.
Lesson learned, never make round curves in polycarbonate!
To hold the corners of our speakerbox, we use a two-component poly-urethane glue (3M Scotch-Weld Urethane Adhesive DP-610). We got a test-sample from KA Olsson and it worked really great. It’s quite expensive, but we got it a little bit cheaper thanks to KA Olsson.
We used straps to tighten the polycarbonate around the corners. We also applied tape at the edges to stop the glue from seep out.
For my and Vilses speaker-backpack it’s really crucial that we bend our angles straight and in the right angle.
We developed our own heat bending machine to make straight bends, but we needed a fixed angle to bend it in the correct angle.
So we extracted all the angles from our CAD-drawing and placed them on a new drawing. We had this idea about a multi-angeled hexagon, containing all the angles needed.
But we couldn’t fit all angles on one sheet, so we had to make two sheets.
After that we cut the angles with the laser-cutter, we also wrote the angles on top.