ULTRA BOARD is a lightweight structural panel consisting of a rigid
polystyrene foam core faced on both sides by a smooth, moisture
resistant sheet of solid polystyrene. The foam and facers are
permanently bonded together. The face laminates have been specially
developed to provide an excellent surface for painting, silk
screening, photo mounting and vinyl lay up. Together with these
properties and the ease and multitude of shaping methods make ULTRA
BOARD an excellent choice for signage, photo mounting, exhibits,
point of purchase displays and routed letters.
ULTRA BOARD panels are a strong, moisture resistant material. When
exposed to long periods of very moist conditions, there is little
change in either the face or the core. Exposure of unprotected faces
to exterior conditions has no effect other than a slight bleaching.
Ultra-violet radiation degrades unprotected foam. Therefore, any
exposed foam should be protected with a good quality, pigmented
water base coating or other U.V. barrier. Large panels should be
well supported to protect against any bowing movement. Caution
should be taken when using darker colored inks and paints. Dark
coated ULTRA BOARD panels may blister when exposed to direct
Under most conditions ULTRA BOARD panels will not warp; however,
they may bow under certain conditions. Potential for bowing is much
greater in thinner panels and in full 4 ft. x 8 ft. unsupported
panels or on panels that are treated differently on one side than on
the other, e.i., coating panels on only one side or exposing one
side of the panel to a higher heat source than the other.
ULTRA BOARD panels are manufactured and packaged flat; occasionally,
however, a panel may tend to bow after unpacking. These panels
should and can be corrected by inverting the panel on a flat surface
and allowing it to remain inverted (1-24 hours) until the warping
has dissipated. To insure maximum flatness, full wood frames edge
glued to the perimeters of the panel should be sufficient. Extruded
aluminum channels or wood frames to fit panel edges also work well.
For extremely critical applications, a thicker ULTRA BOARD panel
should be used. For panels where coatings cover 50% or more of the
surface area, it is advisable to similarly coat the opposite side.
Standard ULTRA BOARD panels have 0.015" litho grade high impact
polystyrene facers. ULTRA BOARD is also available with 0.030"
facers. Colored facers are available on a custom quote basis. It
should be noted that this technical bulletin only covers ULTRA BOARD
panels with the standard facer.
ULTRA BOARD panels are supplied from the factory in two forms:
trimmed and untrimmed. The least expensive form is the untrimmed
panel. An untrimmed panel is a slightly oversized panel in which
either the foam core or the facer material is larger than the other
on one or more sides. Untrimmed ULTRA BOARD is packed on skids
containing 40 inches of material. Trimmed ULTRA BOARD is simply an
untrimmed panel cut to size (48" x 96") such that all the edges are
clean, smooth and square. Trimmed ULTRA BOARD panels are boxed in
Pcs. / Carton
ULTRA BOARD may be cut with standard table saws. For best results,
use a blade designed for cutting ULTRA BOARD. The specifications
- Top grind inverted "V"
- Face grind hollow
- Tooth pitch 0.375" to 0.750"
- Side clearance 0.015" to 0.020"
- Clearance angle 2°
- Blade rpm 3500 to 4500
- Feed rate 40 to 60 fpm
Or, you can purchase an ULTRA BOARD saw blade from Arkansas Carbide
Saw and Tool,(918) 626-3837. Let them know arbor and blade diameter.
Routing of ULTRA BOARD works well for creating irregular shapes. We
recommend bits available from Onsrud Cutter, Inc., (847) 362-1560
and Vanguard Tool Corp. (540) 673-3496. Use Onsrud Cutter series
52-200 or Vanguard Tool part number VSC-102. Router bits should be
double fluted carbide, upward chip removal, with a 1/4” shank
diameter and a 3/16” cutting diameter. For best results run at
18,000 rpm and 85 inches/minute. Feed rate may be varied to
compensate for larger bit diameter and different rpm. For special
and long router bits for CNC routers, we recommend contacting
Hartlauer Bits (541) 343-0390.
3/16" and 1/2" ULTRA BOARD die cut very well. Die cutting ULTRA
BOARD is not recommended for panel thicknesses greater than 1/2".
3/16 inch and 1/2 inch ULTRA BOARD guillotine cut very well.
Guillotine cutting ULTRA BOARD is not recommended for panel
thicknesses greater than 1/2 inch.
While ULTRA BOARD can be cut by hand, the strength of the face
surfaces makes it difficult. For straight cutting by hand, best
results have been achieved with knives with thin blades.
LAMINATING / GLUING:
No special surface preparation is required when gluing to the face
of ULTRA BOARD. The surface should be kept clean and free of any oil
contaminates as with any other surface to be glued. Great care
should be taken in choosing an adhesive, however. Some solvent based
adhesives will attack the styrene facer causing a small hole to
develop in the facer thus allowing the adhesive to deteriorate the
bond between the core material and the facer. This reaction could
take up to several days to develop. Any adhesive should be
thoroughly tested to evaluate its suitability. We recommend using
Latex Liquid Nails for Foamboard, part number LN901. This adhesive
is available from most hardware stores.
ULTRA BOARD needs no special preparation before priming or painting.
For best results the surface should be clean and free of any oil
contaminates. This can be accomplished by cleaning the panel with
glass cleaner or isopropyl alcohol just prior to coating. In any
case the surface should not be sanded.
TYPE OF PAINT:
The following paints have shown excellent results when used on ULTRA
Sterling Paint (800) 999-8482
Medallion Enamel (no primer necessary)
Sherwin Williams (800) 336-1110
A-100 series latex (no primer necessary)
Devoe Paint (800) 654-2616
Mirrolac WB 8300 - 8400 series (no primer necessary)
Mirrolac WB 8502 series (no primer necessary)
AKZO Nobe (800) 233-3301
Grip-Gard HS (must be used in conjunction with VPS-1 primer)
Grip Flex (no primer necessary)
Grip Flex AQ (no primer necessary)
Matthews Paint Co. (800) 323-6593
MAP (must be used with 74-777 Tie Bond primer)
VOCMAP (must be used with 74-777 Tie Bond primer)
SVOC MAP (must be used with 74-777 Tie Bond primer)
1 Shot (219) 949-1684
Acrylic Graphic Coat Bulletin
Art and Sign Poster Colors
Caution should be taken when using oil base or solvent base systems,
not to allow paint to make contact with the polystyrene core. These
types of paints are likely to attack and deteriorate the foam core.
In cases where the foam edges might be subjected to exterior
exposure, it will be necessary to protect the edges from
deterioration by the high intensity ultra violet light of the sun. A
good coating of water-base paint or similar U.V. barrier should be
sufficient to provide this protection.
Caution should be taken with any paint, especially when intended for
outdoor use. Always test paint on ULTRA BOARD prior to production
run and follow all of the paint manufactures instructions.
ULTRA BOARD panels are rigid, lightweight and easy to handle. The
facers accept most printing inks well. Our experience shows NAZ-DAR
79000 series corogloss ink and Ink Designs Modified Acrylic works
well. Caution should be taken with any ink. Always test ink on ULTRA
BOARD prior to production run. Allow 24-96 hours after test printing
to evaluate the suitability of the ink for the intended application.
And follow all of the ink manufacturers instructions.
For best results in silk screening ULTRA BOARD panels, it is
recommended the panels be cleaned to avoid the clogging of screens.
This can be accomplished by wiping the panel with a tacky cloth or
by cleaning the panel with isopropyl alcohol or glass cleaner prior
Drying by oxidation and evaporation is recommended. Allow the
freshly printed ULTRA BOARD to dry the length of time suggested by
the particular ink manufacturer.
ULTRA VIOLET INKS:
U.V. inks can be used with ULTRA BOARD. However, board thickness,
type of ink, wattage of U.V. lamp and exposure time can affect
results. Always test the suitability of the ink and the drying
process for your particular ULTRA BOARD thickness. Allow 24-96 hours
after test printing to evaluate the results. And follow all of the
ink manufacturers instructions.
ULTRA BOARD panels work well with digital printing equipment.
However, new equipment is constantly entering the market. Existing
equipment continues to be upgraded and modified for existing
substrate technology. Before printing a production run of ULTRA
BOARD, it is recommended that the end user call the manufacture of
digital equipment for set up and ink recommendations. ULTRA BOARD
may not be an appropriate product for every flat bed application.
United Industries offers a free digital sample kit for testing
before setting up for a production run.
It is recommended before printing ULTRA BOARD that all panels are
cleaned of any surface contaminates. This can be accomplished by
wiping the panel with a tacky cloth or by cleaning the panel with
isopropyl alcohol or glass cleaner.
Cotton gloves must be worn when handling ULTRA BOARD.
ULTRA BOARD panels are being used extensively in pressure sensitive
photo mounting. The facers of ULTRA BOARD make it a superior panel
for photo mounting.
The surface should be clean and free of any dust, oil or other
contaminates prior to mounting. This can be accomplished by wiping
the panel with glass cleaner, a tacky cloth or with isopropyl
PRESSURE SENSITIVE MOUNTING:
The choice of film is the most important consideration when using
pressure sensitive film for mounting photographs to ULTRA BOARD.
Before using any pressure sensitive material, contact the
manufacturer for recommendations concerning the use of their
respective laminating materials in conjunction with ULTRA BOARD. For
best results, the use of equipment specifically designed to apply
these pressure sensitive films should be used.
Dry mounting is not recommended with ULTRA BOARD. The panels tend to
warp when heat is applied to only one side of the panel.