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The Laser Absorbent Panel

A professional looking absorbent panel

Introduction

The Laser Absorbent Panel is a digital manufacturing solution to reduce the reverberation of a room. Absorbent panels are the first acustic elements we introduce in a recording or control room. 

Tools and Materials

Step 1: Take the CAD to a local laser machine

Download this CAD v1.4.4 file and take it to a laser machine. You can find a local laser machine using the Fabhub site or the yellow pages. If you live next to a FabLab you can contact them to know when there is an open day.

Laser Cutting v1.0

Test your dimensions & material specifications.  When we use .dxf files not all softwares maintain original dimensions. When original dimensions have changed we need to rescale the .dxf file to the original size. We provide a diagram so you know you are in the right track.
(Don't worry if you are not familiar with cad files, the person with the Laser Machine will know).

Other times, the boards we have, don't measure exactly the 3mm we need. In this cases it is important to rescale the .dxf file, from the 3mm to the actual size of the dmf board we have. Don't worry about having to check for every board. Usually all boards bought the same day in the same place have the same deviation.

Change from 3mm to actual dmf board thickness

Step 2: Glue the frame pieces together

They are designed so they can not be mounted the wrong way. If they fit, you're doing great. We recommend that you fit the pieces together while pressing them horizontally in a table. Repeated task are some times a good idea. Think of preparing frames for all the panels you can produce in a day (between 10-20). 

Special attention for wall mounted panels ! check diagram under video

The latest design Laserpanel has two versions, one design for ceiling installation and another design for wall installation.
When assembling special wall installation frames, it is important that the two frame pieces with hanging support are positioned opposite of each other.

position the two pieces with hanging support opposite from each other

Step 3: Glue the fabric to the frames

Before we start we need to prepare fabric rectangles measuring 58x58cm. In order to glue the fabric to the frames we will use a hot glue gun. First start with one corner and tighten the fabric as you move onto the other 3 corners.

Continue along the sides and seal.

Step 4: Attach the pestañitas to the box pieces

Pestañitas are the small pieces which hold the box and the frames together. When attaching them with the box pieces you will feel and hear a click.

Step 4: Put the box pieces together

Glue one box at a time. This is important because the glue dries relatively fast. Remember you are gluing in two dimensions, all contact surfaces must have glue.

Stick the box pieces together.

Box ready !!

Step 5: Join the bottom frame with the box

Glue the top edge for comfort. Remember all contact surfaces must have glue. 

Align the pieces and press with care.

Step 6: Insert the Rockwool into the box.

Start cutting Rockwool rectangles measuring 58x58cm. 

Then insert gently the rockwool (or fiberglass) into the box and remove the excess material.

Step 7: Close the box.

Repeat step 5, make sure the rockwool is not too tight.

The finished Laser Panel

Now you should have your very first Laser Absorbent Panel in your hands. I hope it looks great, but don't worry if it's not perfect. You will do it better with the next ones now that you know the process.

A Laser Panel in the woods

This tutorial is still quite new. If you think something is not explained enough or you got stuck somewhere, we really wanna know. Please send us an email to [email protected].

Any suggestions, any questions, anything... yes, we are at [email protected].

Has it helped you? Did you build it? Would you improve something? Please don't be shy, we take feedback really really well :)

Thanks!


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