Acell has over 25 years experience in the production and manufacture of composite products, using many moulding techniques included hand lamination, injection, compression and resin transfer moulding.

These processes have limitations in high volume production, as they are only one of a number of processes needed to manufacture a complete composite product. Using these methods, the additional separate processes required to complete a composite panel include the bonding the skin to a substrate or sub-frame and in the case of an entrance door, the subsequent injection foaming of the void between the skins.

The Acell manufacturing process will, in one step, form the finished panel facings by placing them directly onto both faces of the substrate/sub-frame and foam using high definition in-mould technology to produce multi-colour and multi-tone finishes. This single step process also eliminates many of the problems associated with composite materials such as:

• Delamination
  
  
• The SMC compound is moulded and adhered to the Acell foam during Acell’s manufacturing / moulding process resulting in a composite structure made in one production step.
• The specially formulated SMC flows into the open cell structure of the Acell Foam, and provides a mechanical bond
  
  
• Voids within the panel caused by incomplete foaming
  
  
• Integrity of the Acell Foam is controlled during foam production and conversion
  
  
• Entrapped gases within the panel which often cause bubbling of the surface or warping when exposed to the elements (sunlight)
  
  
• Acell Foam is fully cured during production prior to conversion and manufacture of the composite panel

The Acell process eliminates these issues in a cost effective and efficient manner.