Aluminum Imitation Stone material achieves a texture effect highly consistent with natural stone on the surface of aluminum panels through precise process design. Its core lies in the combination of multi-layer coating technology and digital control. The production process uses high-grade aluminum alloy sheets as the base material. First, it is processed into the required shape through CNC bending and welding, followed by surface treatment—a crucial stage determining the accuracy of the texture simulation.
In the coating process, fluorocarbon spraying technology dominates. Its typical process is "three coats and two bakes": first, a primer is sprayed to form an adhesion layer; then, a topcoat and clear coat are sprayed in layers using a computer-controlled automatic spray gun. Each layer requires high-temperature baking for curing. During this process, the paint formula must be precisely formulated, simulating the natural color differences of stone by adding different color pastes. For example, light gray paste is added to the primer to establish the base tone, while the topcoat uses layered dark gray and beige dots to create a sense of depth. Temperature control during the baking stage is particularly critical; too high a temperature will cause the coating to crack, while too low a temperature will prevent curing. It must be strictly maintained between 220-250℃ to ensure coating stability.
To achieve more complex texture effects, some processes incorporate pre-roll coating or spray dotting techniques. Pre-roll coating uses continuous roller pressing of fluorocarbon paint to imprint stone textures onto the surface of aluminum coils, followed by a five-coat, five-bake curing process. This method is suitable for mass production of standardized textures. Spray dotting technology uses an electrostatic atomizing spray gun. By adjusting the spray gun pressure and paint viscosity, irregular color spots are formed on the aluminum plate surface, simulating the natural speckled effect of stone. For example, when spraying red stone textures, the spray gun pressure needs to be controlled at 0.3-0.5 MPa, with 4-6 coats to ensure a natural distribution of color spots.
The introduction of digital technology further enhances texture accuracy. Texture data of natural stone is acquired using 3D scanning technology, converted into a digital model, and then the pattern is numerically positioned using high-precision spraying equipment. During multiple coating and baking processes, the system automatically adjusts the spray gun path and paint flow based on the model, ensuring that the texture direction and color difference distribution of each aluminum plate are highly consistent with natural stone. For example, when replicating marble textures, it's crucial to capture its flowing, vein-like characteristics. By adjusting the spray gun's reciprocating speed and spray angle, the texture on the aluminum panel surface achieves a natural, extended feel.
Color management is another core aspect of ensuring texture consistency. A standard color chart system must be established during production. By comparing with natural stone samples, the closest paint formula is selected. For multi-batch production, each batch of aluminum panels must undergo color difference testing against the standard color chart. The ΔE value must be controlled within 1.5 to ensure no visible color difference between batches. Furthermore, the selection of paint suppliers is paramount. High-quality suppliers must provide fluorocarbon paints certified to the AAMA2605 standard, ensuring the aluminum panels will not fade for 10 years in outdoor environments due to their weather resistance and UV resistance.
Post-processing techniques play a crucial role in perfecting the final texture presentation. Some products have a transparent protective film applied to the coating surface, enhancing wear resistance and improving the texture's three-dimensionality through the film's refractive effect. Other processes employ brushing or polishing to create subtle gloss variations on the stone surface, simulating the light and shadow variations of natural stone. These meticulous details make aluminum imitation stone materials more visually and tactilely similar to real stone.
From an industry trend perspective, the texture processing of aluminum imitation stone materials is developing towards intelligence and personalization. Optimizing coating formulations through AI algorithms or combining them with AR technology to achieve real-time texture previews can further shorten the R&D cycle. Meanwhile, with increasing environmental protection requirements, the application of water-based fluorocarbon coatings and low-VOC emission processes will also become a key focus in the future, reducing the environmental impact of production while maintaining texture simulation.
