Dibond is an aluminium composite panel made of two thin aluminium skins (approx. 0.3 mm each) bonded to a polyethylene core. This combination delivers a material that is simultaneously lightweight, rigid and weather-resistant — which is why Dibond has become the dominant choice for outdoor signs, façade cladding and trade-show displays. See the available Dibond formats and finishes in our offer.
Types of Dibond Panels
Manufacturers offer a wide range of surface finishes:
- White / black Dibond — polyester matt coating, the standard choice for signs and enclosures
- Brushed Dibond — imitation brushed aluminium, popular in premium advertising and architectural elements
- Mirror Dibond — high gloss, used for 3D letters and logotypes
- Anodised Dibond — electrochemical coating, higher scratch resistance
- Print-ready Dibond — with a surface layer prepared for UV or screen printing
Standard panel thicknesses are 2, 3 or 4 mm. Sheet format is typically 1500×3050 mm or 2050×3050 mm.
CNC Routing Parameters
Dibond is a two-layer material — the aluminium behaves differently from the PE core. The key is efficient chip evacuation to avoid tool galling:
- Spindle speed: 18,000–24,000 rpm
- Feed rate: 4,000–8,000 mm/min
- Cut depth: for 3 mm — full depth in a single pass; for 4 mm — two passes
- Cutter: single-flute aluminium-specific (O-flute), or double-flute compression bit
- Cooling: compressed air is sufficient; avoid coolant emulsion (contaminates the PE core)
Climb milling produces cleaner edges on the aluminium face than conventional milling.
Engraving and V-Groove Bending
One of the unique techniques for Dibond is V-groove routing — a 90° cut through the aluminium and part of the core, without cutting through the second skin. This allows the panel to be bent at an angle to form a three-dimensional shape — cassette letters, channel lettering, device housings.
The groove angle is selected according to the desired bend angle (a standard 90° groove = a 90° fold).
Dibond vs Other Materials
| Feature | Dibond | Acrylic | Plywood |
|---|---|---|---|
| UV resistance | ✓ | ✓ | ✗ |
| Rain resistance | ✓ | ✓ | Treated only |
| Weight (3 mm) | ~4 kg/m² | ~3.6 kg/m² | ~6.5 kg/m² |
| Bending | V-groove | Thermal | ✗ |
| Price | $$ | $$$ | $ |
| Metal aesthetics | ✓ | ✗ | ✗ |
Common Mistakes When Machining Dibond
1. Wood cutter. Wood router bits have the wrong cutting geometry for aluminium — they dull quickly and leave burrs on the edges.
2. Feed rate too low. At insufficient feed rate the aluminium is not cut — the tool rubs the material, generates heat and burns the edge.
3. Skipping the spoilboard. When the cutter breaks through the Dibond it must enter a sacrificial board (MDF or spoilboard) — without it the bottom edge is ragged.
4. Clamping. Thin Dibond sheets can lift off vacuum tables when they have holes cut through them. Use mechanical clamps for smaller formats.
Applications
- Outdoor signs — information boards, building facades, house numbers
- Letters and logotypes — CNC-routed, wall-mounted or backlit
- Trade-show and exhibition stand construction — walls, displays, counters
- Façade cladding — wall panels for office and commercial buildings
- Industrial labelling — machine nameplates, safety signs, zone marking
- Interior fit-out elements — suspended ceilings, reception desk cladding, decorations
Tolerances and Finish
With correct CNC parameters we achieve tolerances of ±0.1 mm on external dimensions. Dibond edges after routing are generally mount-ready — the aluminium layer is visible, giving a "metallic edge" effect. Optionally, edges can be de-burred or powder-coated.
Have a project involving outdoor signage or façade advertising? Learn more about our CNC milling services or request a quote — we respond within 24 hours.