I recently managed to get a bunch of large used Corflute sheets and I have been trying to find some purpose for them. Corflute is a really strong material used by Real estate agents (usually) to make promotional boards that go outside open homes etc. Schools and Politicians also use them for their advertising. It is usually printed on one side for an event, and then it is discarded.
The Robocup Search and Rescue layout is made out of tiles (roughly 590mm square) on a large vinyl mat. Since it has to be cut up to be used for the challenge, I thought the corflute would be ideal to make the base for each of the tiles. Each corflute sheet was 1200 x 800 giving me ample space to get two tiles on each sheet.
Cutting corflute is easy as long as you are going with the grain (long parallel framework inside). Use a Stanley knife and you are good to go. If you go against the framework, then you need a fine-toothed handsaw (or a Dremel if you don’t have patience). It is a tough material and using a knife can be difficult, despite what the internet says.
Sticking Vinyl on Corflute is another challenge. Your regular PVA or Liquid nails won’t work. You will need contact adhesive. Look for what your local hardware store provides but for me a spray contact adhesive worked just fine. Make sure you spray it in an open area and take precaution when using it. Use a mask and eyewear.
Once done, finish up the edges of the tiles using some sort of sanding tool like a file or a small sanding attachment with a Dremel (that’s only if your edges are not straight, like mine).
I am planning to use Corflute to make frames / chassis for robots as you can screw motors directly on it. If you have kids, you can even probably make doll houses or shelves for hot wheels with corflute.