Wednesday, 1 April 2026

Copper foil – to grind or not?


This is a question which always has two entrenched sides.  One for always doing it; one for grinding only when necessary for shape.


Some facts:

  • The glue on foil is an impact adhesive.

  • Impact adhesives stick most securely to smooth surfaces, and resins stick well to roughened surfaces.

  • The adhesive is severely weakened by the heat of soldering.


It is a misconception that the adhesive on the back of copper foil tape is a structural element of panels. The adhesive is a temporary means of fixing the foil in place. The heat of soldering seriously degrades the adhesive. 

Therefore, the adhesive can only be a temporary measure to hold the foil in place while the came-like solder structure is created.

The structural element of copper foil panels is in the fin of solder connecting the beads on each side. This forms a came made of solder instead of lead. To be sound, there needs to be a domed bead of solder on each side with solder connecting them.


It doesn't matter in the long term whether the foil sticks well to the glass or not. Yes, it is easier to work if it does stick, but the strength remains in the came formed of solder.

Not every score and break is perfect, and often grinding is required to fit the pieces together. But when the score is exactly what is needed, there is no reason to grind it. The adhesive will stick better to the smooth than the roughened surface.


My conclusion is that it does not matter which side of the grinding issue you support. But why go to extra effort of grinding when there is no noticeable effect in the end? 

It is the came that is created by the fin of solder joining the beads on each side that provides the strength in copper foil panels.

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