Parts Fabrication from Aluminum Composite (Hylite)

Hi anyone

I have a project (mass production, several thousands pcs) in aluminium composite. The material is Hylite from Alcan. It is a laminate material comprising two thin aluminium layers (0.2mm each) with a polypropylene core, rubber like, (0.8mm and very flexible and resistant). The main advantage of this material that it can be bended over and over again if the two layers of aluminium are removed (through grooving) as the remaining core is flexible. This eliminates the need for any supplementary part in joints .

- the main operations are then cutting, grooving and bending. The cutting might be necessary to be done sometimes with 1 mm wide channel throughout the entire material. Holes might me necessary, with a diameter of 3mm. The grooving should be done as to remove the aluminium layers on both sides, without affecting the core to much (leave 0.6 mm intact out of the entire 0.8 core). The grooving angle is 135degree.

I am looking for technological options for such operations. I am intrerested in the best option but also looking for the cheapest as well. As it is mass production, the processing time is important as well.

I am considering cnc router as an option, but i don't know if such machines can deal with such thin material. Laser would be also an option, but again, not sure if the material resists to this treatment.

Suggestions about technology and machines are highly appreciated

Regards

Marius