MICRO MILLING™ is a technology developed by Melaco that allows for micro-milling of foil-covered furniture fronts. Unlike traditional milling in MDF boards, micro milling does not interfere with the structure of the board itself, but with the foil layer, which is usually 200 to 300 micrometres thick.

The process involves the extremely precise removal of the top layer of foil using computer-controlled milling cutters. Thanks to the use of specialised software, it is possible to create a variety of patterns while maintaining full control over every detail.

One of the greatest advantages of micro milling is the variety of visual effects available. This technology allows for the creation of both simple and elegant lines as well as more complex ornaments. The patterns can be geometric – for example, parallel lines, rhombuses or waves – or organic, inspired by natural wood surfaces.

It is also possible to create frames and borders that give fronts a more classic look. Importantly, all these patterns are fully repeatable and can be used in mass production. This allows furniture manufacturers to introduce decorative elements into their collections that were previously difficult to achieve while maintaining high quality and repeatability.

Durability is one of the most common topics discussed in the context of micro milling. In this case, the key factor is that milling only affects the top layer of the film. Since the cuts are very shallow, they do not adversely affect the strength of the entire board.

The films used in this technology, PCV and PET, are highly resistant to moisture, high temperatures and scratches. In addition, PUR adhesives are used in the production process to increase the strength of the joints and protect the surface from deformation. As a result, fronts with milled film are durable, easy to clean and retain their aesthetic properties for many years.