Saw Cutting:
Usually vertical panel saws of good quality are being used. Even portable circular saws equipped with a system of guides can be used, so as to ensure straight line cuttings.
  Circular Routing Blades and Router Bits:
The Main Feature of ALUTUFF panels is that they can be routed through local panel routing machine to internationally designed vertical panel saws including hand panel routed with various kinds of routing blades.
Shear cutting can also be used for sizing a large quantity of ALUTUFF Panels. Some shear drop may be observed at the cut edge.
  Bending With Brake Press:
While bending the ALUTUFF Panels with press brake, use of top die having the desired radius.
Bent Tray Panels:
ALUTUFF Panels can be bent after routing to any shape desired with proper cuttings to the collars.
Grooved ALUTUFF Panels can be bent with jig, press brake or plate punch.
Bending With 3- roller Bender:
ALUTUFF Panels are bent in 3-Roller bending machine for larger bending radius.


ALUTUFF Panels are recommended to route to below details of correct routing depth for different bending applications. The routing tools recommended are Vertical panel saws or CNC routing stations. If fabrication is done on site then hand routing machines can be considered with a carbide tip cutting tools. In any routing method a thin layer of the core material should be left at the base of the groove, i.e. on the inside of the outer cover sheet. The untouched outer cover sheet can now be bent manually, giving an exact and clean folding line which follows the routed groove.

ALUTUFF panels can be shaped using a very simple fabrication method. The technique, called the routing and folding method, enables a fabricator to produce shapes of various kinds and sizes. A V-shaped or rectangular groove is routed on the reverse side of the ALUTUFF panels using a disk or end milling cutter. Then folded carefully to desired shape of different sizes with clean folding lines.

Apart from the routed tray panel system, other techniques can also be adopted using various tapes and sealant adhesion system, which should be followed strictly in accordance with the respective tape or sealant
manufacturer's recommended fabrication method.

Note : The cutting or routing tools should not generate heat (happens in non carbide tip tools or multiple attempt of routing) while routing or cutting. Care must be taken to replace the cutting or routing tool to prevent damages to the panel.

Details of various types of circular blades and router bids are shown in following figures.