Polyester Fibre
Acoustic Boards

A polyester fibre acoustic board is a rigid panel manufactured by thermally bonding recycled polyester (PET) fibres into a dense substrate without chemical adhesives or binders. The fibres self-bond under heat and pressure at 180 to 200 kg/m³. The compressed board is then precision-machined to the finished surface profile. Because no adhesive core is added, the material is structurally stable across the full thickness and can be CNC-machined to complex profiles (fluted, grooved, perforated, three-dimensional) without delamination at the cut edge.

Post-consumer PET bottles are mechanically shredded and extruded into fine polyester fibres. The fibres are cross-lapped in layers and needle-punched to interlock the matrix before thermal pressing. Pressing at elevated temperature causes the PET fibres to soften and fuse at contact points, bonding without any adhesive or chemical binder. The pressed sheet is cooled, cut to standard sizes, and then CNC-machined to the selected surface profile. No formaldehyde, no VOC-emitting compounds, and no mineral content is introduced at any stage.

U-TONE polyester fibre boards achieve NRC ratings of 0.70 to 0.90 depending on the surface profile and thickness. NRC (Noise Reduction Coefficient) measures absorbed sound energy on a scale of 0 to 1. Thicker profiles (24 mm and above) and boards installed with a 25 to 50 mm air gap behind the substrate consistently achieve the upper end of the range. Testing is to ASTM C423. Third-party test reports are available on request from the specification desk.

Yes. Polyester fibre boards are thermally bonded without any adhesives or binders, so there is no VOC off-gassing during or after installation. The surface is not friable and does not shed fibres during normal use or cleaning. U-TONE boards can be disinfected by fog, spray, or wipe without degradation of the surface texture or acoustic performance. They are specified for healthcare settings including AIIMS, where infection control and indoor air quality requirements are stringent.

Polyester fibre and mineral wool both achieve high NRC ratings through porous absorption, but differ on three points important to specification. First, polyester fibre has a self-finished architectural surface machined directly into the substrate: no fabric facing required, 52 colours available. Mineral wool boards need a perforated or fabric facing to present a finished surface. Second, polyester fibre is safe to handle without protective equipment; mineral wool fibres cause skin and respiratory irritation on site. Third, polyester fibre is 100 per cent recyclable as PET at end of life; mineral wool recyclability varies by manufacturer and binder type.

Yes. All U-TONE boards are available in standard sheet sizes (2400 × 1200 mm, 2400 × 600 mm, 1200 × 600 mm) and can be fabricated to project dimensions. Custom shapes, non-rectangular profiles, and CNC-cut surface patterns are available from 12 m² per pattern. Dimensional tolerances are ±1 mm. Polyester fibre cuts cleanly with a table saw, circular saw, or CNC router: no delamination, no fraying at the cut face.

Yes. Polyester fibre does not retain moisture in the way mineral wool does: water passes through the fibre matrix and the board returns to its original dimensions on drying. The wipe-cleanable surface is compatible with standard disinfectant protocols. U-TONE boards are installed in AIIMS and in commercial kitchens, washroom lobbies, and healthcare waiting spaces where humidity and infection control are ongoing concerns.

Standard lead time is 4 to 8 weeks from approved sign-off drawings. Custom CNC surface profiles and non-standard panel sizes are included within this window. Sample boxes ship within 2 working days and contain chips of all eleven board profiles plus a full 52-colour felt swatch deck.