Whether PS Mirror Sheet is prone to cracking or delamination during bending or cutting mainly depends on its material properties, production process and operation method. The following is a detailed analysis:

1. The influence of material properties on bending and cutting
(1) Substrate properties
The substrate of PS mirror sheet is usually polystyrene (PS), which has certain rigidity and brittleness, especially in low temperature environment.
The molecular structure of polystyrene makes it easy to produce stress concentration when bending, resulting in cracks or ruptures.
(2) The influence of aluminum coating
The aluminum coating on the surface of PS mirror sheet is formed by vacuum coating process. Although this metal film gives the mirror sheet high reflective performance, its thickness is usually only a few microns and is very fragile.
During bending or cutting, the bonding strength between the aluminum coating and the substrate may be insufficient, resulting in delamination (i.e. the aluminum coating peels off from the substrate).
2. Problems during bending
(1) Crack formation
When the PS mirror sheet is bent beyond its elastic limit, irreversible deformation will occur inside the substrate, which will cause cracks.
If the bending radius is too small, the brittleness of polystyrene will aggravate the occurrence of cracks, especially in the edge area or where stress is concentrated.
(2) Delamination phenomenon
During the bending process, the difference in thermal expansion coefficient between the aluminum layer and the substrate may cause the deformation of the two materials to be asynchronous, thus causing delamination.
If the adhesion of the aluminum layer is insufficient (for example, insufficient surface treatment during production), even a slight bend may cause the aluminum layer to fall off.
(3) Improvement measures
Optimize the bending radius: Avoid bending the PS mirror panel to a radius that is too small. It is recommended to select an appropriate minimum bending radius based on the material thickness.
Heating-assisted bending: Softening polystyrene by appropriate heating (such as using a hot air gun or infrared heating equipment) can reduce its brittleness and reduce the risk of cracks.

Enhance the adhesion of the aluminum layer: Use primer or plasma treatment technology during the production process to improve the bonding between the aluminum layer and the substrate.
3. Problems during cutting
(1) Crack formation
During the cutting process, the pressure of the tool or saw blade may cause microcracks on the edge of the PS mirror panel, especially when cutting quickly or the tool is not sharp.
If the cutting speed is too fast or the temperature is too high, the polystyrene may melt or crack due to local overheating.
(2) Delamination
During the cutting process, vibration or uneven pressure of the tool may cause the aluminum coating to separate from the substrate, especially in the cutting edge area.
If the cutting equipment is not precise enough, the aluminum coating may peel off or be scratched.
(3) Improvement measures
Select appropriate tools: Use sharp tools or saw blades and ensure the stability of the cutting equipment to reduce impact and vibration on the material.
Control cutting speed: Avoid too fast or too slow cutting speed to reduce heat accumulation and material stress.
Edge protection: After cutting, the edge can be polished or coated with a protective layer to prevent further peeling or damage of the aluminum coating.
4. Precautions in practical application
(1) Preparation before processing
Before bending or cutting, check the thickness of the PS mirror panel, the quality of the aluminum coating, and the uniformity of the substrate to ensure that the material itself has no defects.
Select the appropriate type of PS mirror panel (such as modified PS material with increased flexibility) according to the specific application scenario.
(2) Post-processing treatment
For the edges after bending or cutting, polishing or applying a transparent protective coating can be performed to enhance aesthetics and durability.
If frequent bending or cutting is required, multi-layer composite materials (such as PS+PET composite panels) can be selected to improve overall toughness.
(3) Influence of environmental factors
Temperature has a significant effect on the processing performance of PS mirror panels. In low temperature environments, the brittleness of polystyrene increases, so it is recommended to process at room temperature or slightly higher temperatures.

A high humidity environment may cause oxidation of the aluminum coating, thereby reducing its adhesion, so the processing environment should be kept dry.
PS mirror panels are indeed prone to cracking or delamination during bending or cutting. The main reasons include the brittleness of polystyrene, the fragility of the aluminum coating, and improper processing methods. These problems can be effectively reduced by optimizing material formulations, improving processing techniques (such as heating to assist bending, selecting appropriate tools), and strengthening edge protection.