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by Chad Alan Frazier and Gary Boone
February/March 2008
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| To help meet the needs of designers who require increased design flexibility, PETG sheet made with Eastman Spectar™ copolyester is able to bend and curve, according to realistic criteria, without breakage. This attribute offers the potential for more creative and complex shapes and aesthetics when combined with mechanical fastening. |
With the accelerating rate of new product launches every year, brand owners are faced with an increasingly competitive retail environment in which to market their products. To attract consumer interest in crowded stores, marketers and designers rely upon fabricators to create point-of-purchase (P-O-P) displays and in-store fixtures that are both eye-catching and durable enough to withstand frequent consumer handling. In addition, fabricators need to balance these aesthetic and performance requirements against their own needs for production and supply chain efficiency.
By offering key advantages for fabricators, including exceptional durability, crystal clear aesthetics and design flexibility, PETG sheet is becoming an increasingly popular option for the development of high-end retail displays and fixtures. PETG sheet’s fabrication-friendly attributes also contribute to manufacturing and logistical efficiencies for common display and fixture construction processes, including mechanical fastening.
Mechanical fastening is one of many highly effective techniques to bond materials, such as plastic, wood or metal, when creating P-O-P displays and in-store fixtures. The process is essentially used to join two or more separate pieces of material so that they can function as a single unit. Mechanical fastening is accomplished by pre-drilling holes in the pieces to be connected and securing them together using a mechanical fastener, such as a screw, rivet or bolt.
Fabricators have a number of considerations to make when choosing between different types of mechanical fasteners for projects involving plastic sheet. Rivets are one popular option fabricators can use to easily attach pieces of plastic sheet. Holes are typically drilled slightly larger than the diameter of the fastener in order to allow for expansion and contractions caused by environmental conditions. This also helps to decrease stress on the part, which can reduce display breakage.
Due to their durability and unique functional properties, metal rivets are ideal for joining metal and plastic sheet. Since metal and plastic have different inherent attributes, this is a distinctive advantage for designs that call for the use of both materials. A drawback to using metal rivets, however, is that fabricators must take care not to over-tighten during the fastening process, as this could cause stress on the plastic sheet, increasing the risk of breakage.
If metal rivets are used, softer metals, such as aluminum, are preferred. Significantly less force is needed to attach aluminum rivets as compared to steel ones. Washers should also be used on both sides of the rivet to help distribute localized stress generated in the area around the rivet connection. Due to their ability to generate higher stress levels, steel rivets should never be used to attach plastic sheet pieces together.
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| Ideal for a variety of bonding processes, including mechanical fastening, PETG sheet made with Eastman Spectar™ copolyester offers optimal design versatility and durability for the creation of high-impact, long-lasting retail fixtures and displays. |
Another viable and often used alternative is plastic rivets. As opposed to their metal counterparts, plastic rivets are lightweight and exert less stress around the fastened area. On the other hand, plastic rivets have less strength capability, which can limit options for designs that would benefit from combining plastic with another type of material, such as wood or metal.
The third mechanical fastening option is T-bolts, which may be used to fasten plastic sheet both to another plastic and to other materials. Although T-bolts are sometimes not as aesthetically pleasing as the other two options, they add strength and durability to the parts being fastened. Additionally, their flexibility allows parts to be shipped flat and assembled at the store with basic instructions, reducing production time. They also allow for easy display disassembly.
T-bolts are often used when display and fixture designs call for rotational movement around the fastened area. As with the use of rivets, care needs to be taken not to over-tighten T-bolts, and washers should be used on both sides where possible.
While mechanical fastening can be critical to the functionality of a P-O-P display, the proper material choice can provide unique aesthetics and durability to help increase a display’s impact and lifespan. Whether working with plastic, wood or metal, fabricators are tasked with finding the right material for their projects.
PETG sheet is ideal for a variety of bonding processes, including mechanical fastening. Unlike alternative materials, like acrylic, PETG’s high impact resistance reduces the potential for cracking or breakage during fabrication, shipping and ongoing consumer use or abuse. This durability is also a benefit for both the retailer and brand owner, helping them to create a safer in-store environment and convey a more premium image at point-of-purchase. PETG’s durability can also extend the lifespan of retail fixtures and displays, decreasing replacement needs and saving money.
PETG sheet offers the possibility of deep draws when thermoformed. It also allows complex die-cuts and precise molded details with minimal sacrifice of structural integrity. To help meet the needs of designers who require increased design flexibility, PETG sheet is able to bend and curve, according to realistic criteria, without breakage. This attribute offers the potential for more creative and complex shapes and aesthetics.
As in-store fixtures are commonly required to last for three to five years in high-traffic retail areas, displays need to be kept clean. Offering excellent chemical resistance, PETG sheet can withstand the harsh chemicals included in many common cleaning agents. PETG sheet’s durability also allows it to be downgauged without sacrificing structural integrity. This can create lighter, more cost-conscious fixtures for fabricators and brand owners.
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| During mechanical fastening, washers should be used on both sides of the metal rivet to help distribute localized stress on the plastic sheet. |
Depending on project requirements, two additional, alternative fastening techniques can be employed to create P-O-P displays and store fixtures: solvent and adhesive bonding. While each technique has its benefits, they are typically more permanent methods of attaching plastic sheet and cannot be used to connect different types of materials, such as metal and wood to plastic.
The road to creating the right P-O-P display and in-store fixture can be winding. Finding the correct fabrication process and a durable and versatile material can present a challenge for fabricators.
Mechanical fastening offers a number of advantages for the production of unique displays. A highly effective means of attaching materials, mechanical fastening opens the door for designers to have greater flexibility when designing displays that utilize one or multiple material types. And when combined with PETG sheet, mechanical fastening can help fabricators truly meet the needs of brand owners, designers and retailers by balancing aesthetics, durability and production efficiencies.
Chad Alan Frazier and Gary Boone are technical associates for Specialty Plastics Film and Sheet, Eastman Chemical Company. For more details, contact Garrett Wilburn, global trade media relations, Eastman Chemical Company, P.O. Box 431, Kingsport, TN 37662 USA; (423) 229-2353, e-mail: globalmediarelations@eastman.com, www.eastman.com.
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