Lamination Process: Step by Step
Here’s how we bring privacy smart glass to life at Polytron:
1. Glass Prep
Every panel starts with glass that’s precisely cut to size. It’s then thoroughly washed and cleaned to remove any contaminants.
2. Film & Interlayer Trimming
The Polyvision switchable film is trimmed to the exact shape and size of the glass. A structural interlayer (similar to what you’d find in safety glass or windshields) is also cut to match.
3. Layering
The glass, film, and interlayer are carefully stacked together, think of it like building a very big sandwich.
4. Vacuum Sealing
The layered panel is sealed in a vacuum bag, with all the air removed using high-powered suction systems. This step ensures a clean, bubble-free bond between all the layers.
5. Baking
The vacuum-sealed glass is placed into an industrial oven and baked for hours. This heat and pressure fuses the elements together to form one solid, durable panel.
6. Testing & Quality Checks
Every panel is tested to ensure the switch function works perfectly, clear when powered, frosted when off, and meets our internal quality benchmarks.
For us, we get to use some pretty cool equipment along the way. Our custom built HoverTrolley®, for example, can lift up to 6 tonnes of glass with nothing but air. It’s one of the ways we handle large custom panels safely and precisely.
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