What Is MDF?
It is therefore a lower-cost replacement for natural wood. You get a natural wood looks without having to spend money on expensive wood. MDF is the expenditure of most people.
Also, Read: Top 15+ Best Plywood Brands in India
Advantages of MDF:
- MDF has economic value for average citizens as it is cheaper and cheaper. So, they’re beyond everyone’s scope to buy. You may normally purchase MDF at a fraction of the cost of buying actual wood. By opting to use medium density fiberboard in some parts of the building, you can save money on other items. This offers you a lot of versatility when it comes to the budget of your project.
- 100% recycled material is used, which ensures that no tree is chopped down, meaning that it is environmentally safe.
- MDF is easy to label in a range of colours and is simpler to mold than solid wood. The MDF process is simple to complete. All sorts of colour, paint may be uniformly coated on the MDF is the ideal substrate for the result of painting.
- MDF is a highly engineered device. So it doesn’t have any grain. MDF does not provide ties which can bleach the ground of a piece or make it impossible to mount parts. That’s why it’s easy to cut and drill without the chance of injury. Its density makes it ideal for robots as well.
- MDF is resistant to termites and other insects due to the chemicals used in its construction during the manufacturing process.
- In comparison to natural wood products such as doors, MDF will not expand and contract in heat and humidity.
Also, Read: MDF vs Plywood | What Is MDF | What Is Plywood
Disadvantages of MDF:
- MDF is made of wood, minor quantities of formaldehyde which be degassed during building, although this has mostly drained away by the completion of the development process. The decorated MDF therefore eliminates any health hazard.
- MDF will expand if the water is hit. MDF extracts water faster than timber.
- MDF needs to be heavily maintained – once MDF is broken or damaged, this can be quickly restored or sealed.
- The additives used to make MDF make the substance less child-friendly than most fabrics.
- MDF is softer than natural wood and is not built to withstand extreme stress. It is vulnerable to breaking or breaking up under extreme tension. Long load-bearing The durability of MDF furniture is smaller than that of natural wood furniture.
- Water Absorption.
- Internal Bond Strength.
- Modulus of Rupture.
- Modulus of Elasticity.
Application of MDF:
- Cabinets and Shelves.
- Decorative projects.
- Speaker boxes.
- Doors and door frames.
- Tradeshow booths and theater set construction.
How to Waterproof MDF?
Should not use waterborne polyurethane, since it can not be conveniently attached to the surface of the MDF.
You would need to start with a latex primer or an MDF-specific primer. Using a 3/8-inch paint roller to add the primer and a paintbrush to hit any places that cannot otherwise be touched. Enable the primer to dry for six hours.
Step three is your final layer of paint or sealant; allow at least three days of drying to make the MDF moisture resistant.
What Is MDF Made of?
MDF was produced by disintegrating both hardwoods as well as softwood into the wood fibers, with MDF generally comprised of 82% wood fiber, 9 percent urea-formaldehyde resin glue, 8 percent water, and 1 percent paraffin wax.
The density is usually among 500 kg/m3 (31 lb/ft3) and 1,000 kg/m3 (62 lb/ft3). The range of density as well as categorization as light, specification, or high-density boards is misnomer and confusing.
The density of its panel, once assessed in regards to the density of the fiber that ends up going into the panel, is important.
In the scenario of softwood fiber panels, a dense MDF panel with a density of 700–720 kg/m3 may be termed “ density, while a board of the very same density created of hardwood fibers also isn’t considered an important density.
Fiber Production For MDF
The unprocessed elements that make up a piece of MDF must undergo some certain procedure before they become appropriate.
A large magnet is used to eliminate any magnetic impurity and the materials are kept separate by size. The materials will then be compacted to drain the moisture but instead fed into the refiner, which crushes them into small pieces.
Resin would then be implemented to improve bind the fibers. This combination is put in a very huge dryer that is heated by gas or oil.
This dry mixture is run via a drum compressor fitted with automated systems to ensure proper density and strength. The subsequent pieces are therefore cut to the appropriate length with the manufacturing saw while still warm.
Fibers are processed as individual but intact fibers and vessels, produced in a dry process. The chips are then compacted into small plugs using a screw feeder, heated for 30–120 seconds to soften the lignin in the wood and then fed into a defibrator.
A typical defibrator consists of two counter-rotating disks with grooves in their faces. Chips are fed into the center and fed outwards between the disks by centrifugal force.
The decreasing size of the grooves gradually separates the fibers, with the help of softened lignin between them.
The pulp wants to enter a ‘blowline’ from its defibrator, an unique portion of the MDF procedure. This is an expanded circular pipeline, originally 40 mm in diameter and up to 1500 mm in diameter.
Wax is infused during the first step, that also coats the fibers and is distributed equally by the turbulent motion of the fibers.
The urea-formaldehyde resin is then infused as the primary bonding agent. Wax enhances moisture resistance as well as the resin originally significantly reduces clumping.
The substance dries in the final heated blowline expansion chamber and expands into a fine, fluffy, and light fiber. This fiber may be used or stored immediately.
MDF Manufacturing Process:
It involves some process, such as:
- Wood preparation.
- Resin recipes.
- Press technique.
- Panel sanding technique.
Step 1. Collection-
The first stage of wood processing is the collection and grinding of raw materials or wood residues. Chips and shaves are harvested from sawmills and plywood plantations.
Debarking is achieved while softwood is used (eg. Eucalyptus sp.). Debarking decreases agricultural waste and grits and improves fine grinding.
If required, the softwood shall be trimmed and re-sliced. A chopper can be used for this purpose.
Step 2. Wood Preparation-
Impurities are separated using magnetic metal. The substance is divided into large lobes and small pitches.
The remaining metals are isolated by a magnetic detector. Picked fibers are submitted to news. For this purpose, a side-screw feeder and a plug screw feeder are used.
Water is collected which has an essential role for it. The refiner tears the substance into functional fibres. Foreign items are removed by massive motor units.
Step 3. Curing and Pressing–
The resin is applied after processing to reduce the resistance of formaldehyde and the catalyst is added after refining.
The quantity of resin shall be controlled by the volume required. The scalping roll is used to render a mat or pad with a uniform thickness.
Compression is performed in a couple of stages. They are sliced or trimmed before final processing. A bigger drum is used to compact it onto a single mat or pad. The resulting board is cut before cooling.
Step 4. Panel Sanding–
The finished panels are sanded to a flawless surface. Belts are used and abrasive coating is found. Various ceramic abrasives, such as zirconium alumina, aluminum oxide, are used.
In comparison, silicon carbide is used for smoother surfaces. Double-way grading is performed to boost accuracy.
Anti-static equipment is used to discourage the use of static energy during construction. Static electricity can create excess dust.
Step 5. Finishing–
The very first step of the finishing process is cutting. MDF changes depending on the consistency specifications of the finishing stages.
Cutting short strips: (1-24 inches/2.5-61 cm) specialized devices are used.
Tiny scale cuttings: (42–49 inches/1071–125 cm) die cuttings are used.
Broadsheet cutting: (e.g. 100 inches) Guillotine cutting is used.
Laminate is the second level of finishing. The fiberboard is being sent among two rolls of paper. The adhesives are subjected to two rolls.
As a result, the fiberboard is coated with adhesive. Vinyl, foil, etc. are being used in the last covering. They are fitted with a lamination system.