The World's Leading Aluminum Composite Panel Fabrication System

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PANELBuilder: The leading CNC routing solution for the aluminum composite market, enabling CNC users to design, nest and program machine panels with ease.

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Who is it for?

Purpose built for manufacturers processing large volumes of cladding materials in the fastest and most efficient way possible. 

What makes it unique?

The PANELBuilder system is the most sophisticated all in one solution on the market. By combining an advanced, easy to use software solution with a custom machine design it is now possible to process all types of cladding materials faster, more consistently and at a lower cost than ever before. 

What materials can PANELBuilder cut?

PANELBuilder is designed to process all types of composite sheet materials such as Alucobond (Alcan Composites), Alpolic (Mitsubishi Chemical), Reynobond (Alcoa) and others.

It is also equally capable of working with other cladding materials such as stainless composite material, titanium, copper or zinc as well as solid aluminum and high pressure laminates such as Trespa.



Why use PANELBuilder?

Renowned as the world’s leading panel fabrication system, PANELBuilder is a complete design, programming and machining package for Architectural metal fabricators. 

The conventional approach to the production of these panels has been to use panel saws, guillotines, notches and turret punches. This is all extremely labour intensive and requires panels to be continually moved from one station to another. Consistency and reliability of output is also a major issue where multiple machines and operators are involved.

The PANELBuilder solution starts with the software which operates in 2D and 3D and allows users to quickly and easily build up a library of panels by either using the built in powerful drawing package or by importing existing drawings. The software will then automatically generate machine toolpaths for cutting all of the panels on the AXYZ CNC Router.

Typically, hundreds or even thousands of panels will be required in a single project. It is therefore important to maximise the material utilisation to reduce costs and keep scrap to a minimum. PANELBuilder incorporates a sophisticated nesting algorithm which can cope with both simple and complex panel geometry to reduce process time and maintain high levels of efficiency.

The AXYZ CNC Routers with their well-established dual and triple head configurations are ideally suited to the processing of composite materials. Most applications require either two or three tools to process the sheets.

The AXYZ twin and triple spindle machines eliminate the need for a tool changer and therefore allow much faster processing times. Typically, one spindle would have a V or ball nosed tool for cutting the fold lines, a second spindle would have a straight tool for cutting the panel out and a third spindle would be used for drill holes. Switching between tools is all handled automatically by the machine controller and results in a fast, seamless machining operation.

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The PANELBuilder CNC Routers from AXYZ International are designed specifically for processing large volumes of ACM and MCM sheets in the fastest and most efficient way possible. The machine itself can be configured to suit your exact needs. Process areas can be selected from 60” (1,524mm) x 120” (3,048mm) to a massive 85” (2,159mm) x 478” (12,129mm) or even longer in increments of 24” (600mm), allowing one or more standard size sheets to be processed at once.

A typical PANELBuilder Router will have two or three cutting heads which allows a virtually instant change between tools used for grooving, drilling and profile cutting and eliminates the need for an automatic toolchange system. Alternatively, a single or twin head setup working with a 7, 21 or 33 station automatic toolchanger can also provide a flexible solution and may be more suitable for some requirements.

Typical PANELBuilder Systems


AXYZ 5018 

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Process Area: 72" x 216" (1,842m x 5,486mm)

AXYZ 5034

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Process Area: 72" x 408" (1,842m x 10.363mm). Higher throughput can be achieved with a pendulum processing system.

AXYZ 6018

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Process Area: 84" x 216" (,133m x 5,486mm). Fabricators who also manufacture cladding from high pressure laminates will often choose a wider machine.

In addition there are a wide range of optional features and accessories which you can choose from to create your ideal solution.

 

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Head Configuration

The 5.0 HP and 10.8 HP HSD Quick Release spindles are incredibly quiet and robust. With a simple yet powerful pneumatic quick release feature, these spindles can be operated manually or in conjunction with our ATC automatic tool changer carousel for automatic changing of tool bits.

Each HSD spindle operates at a maximum speed of 24,000rpm and can accelerate to full speed in a matter of seconds, and brake just as fast. When purchased as part of a cnc router system, three ISO30 toolholders and covernuts are included. Using ER32 collets, you can clamp a routing tool from 1mm to 20mm and quickly change tools as they dull or break or for a secondary process.


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Chip Extraction

The High Capacity chip extraction foot is a vital component of your AXYZ International CNC Router machine. Without excellent extraction of the chips and dust that is created, the mess created can be time consuming to cleanup, and can be a working hazard for your employees. Available with a non-marking contact base for pressure foot operation or a brush ring for non-contact operation.

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Depth Control

The Nose Rider Collar is an AXYZ exclusive machine accessory. Some applications require a very exact depth of cut into the materials, especially for processes that rely on consistent depths for accuracy. Used in conjunction with the high capacity pressure foot, the Nose Rider collar ensures the cutting tool will only protrude through the bottom of the foot to the exact depth required for consistent cutting.


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Material Hold Down

High Pressure vacuum pumps are the standard vacuum hold down pump that is supplied with most AXYZ International systems. Rotary Vane and Rotary Claw pumps are capable of creating a very deep vacuum pressure, and managing the air bleed from the traditional MDF wasteboard used on the aluminium vacuum table. Multiple pumps are often linked together for very large tables, and for applications that may need additional holding power. Lower horsepower (8 to 10 HP) Vane and claw pumps will generally outperform high horsepower blower systems for part holddown.


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Material Location

The hardened steel pins are pneumatically activated to allow fast, repeatable placement of your cutting materials onto the machine. With the full pneumatic retraction, there is no fear of any cutting tool collision with the pin. Configure your machine with a minimum of three pins (three points of contact ensure your materials are on square to the machine), or more depending on your application needs. Because the pins are integrated to the deck of the machine, they are fixed in place and cannot be knocked out of alignment. The 20mm steel pins are extremely robust and can stand up to the repeated impacts of locating materials in place on the bed for the life of your machine.

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PanelPrinter

PanelPrinter is a fully integrated device, mounted alongside the cutting head and designed to automatically print data such as part names, part numbers and 2D data matrix codes onto individual parts as they are machined. Designed primarily for use with the PanelBuilder systems the PanelPrinter eliminates problems and potential errors associated with the manual labelling approach, enabling greater accuracy, easier tracking and a more productive workshop. 

Being able to print 2D Data Matrix Codes as well as standard text, the PanelPrinter is compatible with the 2D Barcode Reader, this enables accurate production data to be easily collected for use in management information systems. 


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Spray Mister

For cutting non-ferrous metals including Aluminium, Brass and Copper, the AXYZ / Spray Misters operate with more precision and reliability than any other dispensing system available. The pulse generator allows for automatic, infinite repeat cycling of the lubricant pump from a single air source. The result is a continuous output of a micro-fine lubricant mist providing longer tool life, better cut finish and higher cutting speeds of non-ferrous metals. Compressed Air Required 80-100 PSI nominal flow required.

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The PANELBuilder Software has been specially developed by AXYZ to meet the needs of Panel Fabricators worldwide.

It is a complete CAD/CAM solution incorporating all of the functionality needed for one-off or high volume panel production. Alternatively, thanks to its open architecture design it can be used in conjunction with existing CAD systems to provide powerful and flexible nesting, automation and machine programming functionality.

Parametric Templates

Create a library of standard panel templates using the built in 2D CAD system. Panels can optionally be saved as a parametric template which allows multiple copies of that panel to be constructed at any desired size with just a few mouse clicks.

Auto Panel Creation from Spreadsheet Data

This is a huge timesaver on large projects and allows hundreds or even thousands of panels to be created in seconds by importing data from a spreadsheet. The data can include panel type, dimensions, material, grain direction requirements and more. 

Nesting and Material Optimization

PANELBuilder contains a sophisticated nesting algorithm which can save an enormous amount of time and significantly reduce waste. The nesting process allows full control of settings such as panel orientation for grain alignment, clearance between parts, common line cutting, part priority and many more. Instant nesting feedback including material utilization allows alternative solutions to be easily assessed.

Automated Machine Programming

Creating the NC programs for the AXYZ PANELBuilder router couldn’t be easier. Whatever your machine configuration the programs are automatically generated ready for downloading to the machine and cutting. Detailed job sheets are printed for the operator to ensure the right material is loaded for each job.

Other PANELBuilder Features:

Batch Drawing Import: If you have a lot of panel designs supplied by a customer or created in other CAD systems these can be easily imported using industry standard DXF and DWG formats.

Multi-Panel DXF Import: Automatically imports and separates multiple panel drawings within one DXF file.

Auto Scrap Cut Lines: Where scrap is unavoidable, the machine can be programmed to automatically cut this into smaller pieces for easier removal and disposal.

Tool Library: Tooling is easily defined and saved in a library for use on all projects.

Cut Sequencing: The order of cutting is automatically set by PANELBuilder but can be manually adjusted if required.

Labelling: Automatic label generation makes it easy to identify and keep track of manufactured panels at later assembly and finishing stages. Labels can be printed or even engraved on the panel and barcode labelling is also supported.

PanelPrinter: The optional PanelPrinter accessory offers fast and accurate printing onto the panels as they are cut.

PanelBuilder AnimationThe most efficient way to manufacture panels is to keep the machine cutting at all times. This is easily achieved using the PANELBuilder 'Pendulum Processing' feature.

This allows the machine bed to be split into 2 virtual zones so that a sheet can be processed on one zone whilst the operator removes the parts and waste from the other zone and a new sheet is loaded ready to be cut. Automatic switching of the vacuum hold down and material locating pins are fully integrated for seamless, continuous production.

The PANELBuilder programming software provides an intuitive graphical interface for scheduling jobs to be cut on each of the virtual zones. Job schedule reports are automatically produced for the machine operator.

The AXYZ PANELBuilder CNC router can be optionally fitted with automatic vacuum zone switching which enables the machine controller to switch bed vacuum zones on and off as required. Auto zone switching can be easily overridden by the operator when needed for processing single large sheets of material.

Pendulum Processing

PanelBuilder

PANELBuilder

The PANELBuilder system is the most sophisticated all in one solution on the market. By combining an advanced, easy to use software solution with a custom machine design it is now possible to process ACM materials faster, more consistently and at a lower cost than ever before. Designed to process all types of composite sheet materials such as Alucobond (Alcan Composites), Alpolic (Mitsubishi Chemical), Reynobond (Alcoa) and others, PANELBuilder is the perfect panel fabrication system.

Watch this video to learn about the high productivity and cost saving benefits that can be achieved.


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Cutting ACM Panels

Use the world's leading panel fabrication system to process panels with speed, efficiency, accuracy and high quality cut edge.

Watch our video to witness high speed grooving and cutting of aluminum composite material using the PANELBuilder System


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Continuous Production with PANELBuilder Pendulum Processing

The most efficient way to manufacture panels is to keep the machine cutting at all times. This is easily achieved using the PANELBuilder 'Pendulum Processing' feature. This allows the machine bed to be split into 2 virtual zones so that a sheet can be processed on one zone whilst the operator removes the parts and waste from the other zone and a new sheet is loaded ready to be cut. Automatic switching of the vacuum hold down and material locating pins are fully integrated for seamless, continuous production.

Watch this video to see the benefits of the pendulum processing feature.


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Barcoding with PANELBuilder

The Barcode Reader can be used to automate certain machine operations such as loading programs and starting the machine. It is a fast and convenient way to improve productivity for high volume manufacturing but also reduces the possibility of errors and wasted materials. Includes scanner, mounting bracket, cabling and software. 

Watch our barcode reader being used for high productivity and improved workflow on an AXYZ CNC Router for ACM Panel Fabrication.