Archive for the ‘ Fabrication Techniques ’ Category

The Angled Light Box


AGAM light boxes just got a little less boxy.

At AGAM we pride ourselves not only on the versatility of our modular system, but on our eagerness to expand our capabilities based on the unique needs of our clients. This kind of innovation is demonstrated most recently by the incorporation of custom degree angle cuts for our FH2001 light box extrusion.

Though our conventional 45 degree miter was previously unchallenged, we received a request for a light box with a slanted edge. We are always excited to broaden our horizons in order to realize a client’s vision and so, after prototyping a solution for that project, we are happy to announce that we now offer custom angles as an option for FH2001 projects in the future.

For engineering details and specifics, please contact

Extendable PH1005 Extrusion

At AGAM, we like to keep an open dialogue with our clients so that we can stay up to date with their needs. After a recent discussion with one of our clients, we found that they were looking for an expandable extrusion that could be used in multiple configurations of a booth.


To address this need we have created a PH1005 that can adapt to 4 different lengths within the meter on center system. The product utilizes two pieces of PH1005, with an In-Line Connector secured with an M4 screw to the shorter 8” piece. The other 29 9/16” piece of PH1005 has four 3/4” holes milled onto the flat face in our Aluminum Machining Center. These holes allow our custom length Push Button In-Line Connector to snap into place in different locations, resulting in an extrusion that move between 1 meter on center, 1 1/4 meter on center, 1 meter diagonal, and 1 1/2 meter on center.

With a CBX42 Connector attached on both ends, this versatile extrusion is ready to be implemented in any structure that utilizes meter on center proportions.





Combination Door Lock

AGAM’s new Combination Door Lock is a substantial upgrade for customers who demand the highest quality, security and flexibility. Unlike other offerings, this new unit consists of an integrated lock and handle rather than separate components.

Keeping up with keys on the show floor can be challenging to say the least.  No longer will you need to decipher which key goes with which lock and receive multiple requests for replacement keys from clients/customers.


With 8,000 possible pass code combinations, the new Combination Door Lock can be tailored to each customer.  Combinations can be changed on show site giving you ultimate control.  And since it offers a matte chrome finish and cast alloy construction, it is built to last.

Technical Details


The Combination Door Lock is available for purchase now and can be purchased as part of a Combination Door Frame Kit (Reference: 818 01).  Please send an email to or contact your sales representative today to receive more information and pricing.

Deflection Calculations

Ever wondered how long of a span you can run without any noticeable sagging? Which extrusion would be best? What about if you decide to hanging a sign from it or mount lighting on top? How much more will it sag then? AGAM has recently developed a formula to calculate the exact amount of deflection for each of its extrusions. No more approximations or educated guesswork is needed by you or your clients!

Based off the common physics equation for beam deflection, our formula works for every extrusion and allows you to input length, number of inline connectors, and load. The formula instantly outputs the maximum vertical deflection, or sag. See the following diagram for a visual description:

C:Usersahartappdatalocalautodeskautocad 2012 - englishr18

For example, a PH1005, our most popular horizontal extrusion, at 16 feet (4876.8mm) in the standard orientation and supporting 10 lbs. will deflect 1.877 inches (47.7mm). However, turning the same piece 90 degrees sideways will result in a deflection of 7.100 inches (180.3mm). This indicates that orientation of the extrusion matters greatly when calculating deflection. For comparison to the standard PH1005, a PH1035, a slightly shorter extrusion, would sag 3.657 inches (92.9mm), while a PH1003, a taller extrusion, would only sag 0.709 inches (18.0mm). See the chart below for comparison of each extrusion:

Extrusion Diagram_Hard Way

Deflection Chart_v3

This formula is extremely useful for many reasons. Not only does it give an exact measurement, but it allows you to choose the optimal extrusion for any given span and load. It helps us engineer a better solution and ensure that your design is structurally sound. No longer will you have to guess whether or not a larger extrusion is worth the additional cost to support your design. And not only does it work well for long spans, but this calculation is also very helpful for shorter bars with heavier loads, such as monitors.

When a span becomes long enough for deflection to become a concern, AGAM also specializes in manufacturing custom length truss. If your design involves heavier loads, this could be the most cost effective solution.

If you would like to calculate deflection for your design or would like to request an extrusion recommendation, please contact any of us here at AGAM and we will be glad to assist you.


FH7690 End Plate

AGAM has created the FH7690 extrusion used in conjunction with the FH7690 End Plate.

As a designer at AGAM, I am continually presented with exciting challenges which enable me to apply my skills and explore my abilities in order to create the best new products for our customers. Recently at AGAM, we have received numerous requests for designs requiring the use of SEG (silicone edge graphics) to turn corners while also being structural enough to create especially large tradeshow booths and displays.  For this purpose we have created a new extrusion: the FH7690 used in conjunction with the FH7690 End Plate. Through design iteration and prototyping we were able to create a system which meets all the prerequisites of our clients.

When I was designing the end cap for this system the key challenge was to create a product that served several functions but was also easy to use.  Another important factor would be its ability to disappear behind our clients’ graphics; by being unobtrusive it would not burden the design of our clients’ displays.

Once I was content with my final prototype, I had to deal with the nuances of full-scale production. Its manufacturing process begins with our Laser Cutting Center, where it cuts aluminum plates of two different thicknesses in order to achieve perfect fitment for our SEG Gasket. These aluminum plates are then inspected and assembled using countersunk screws intended for a flush surface.  These screws are also used to fasten the plates to a custom insert block which can be secured to the new FH7690 extrusion. The finished FH7690 End Plate is then sent through our powder coating oven for a durable painted finish.

Watching the above YouTube video will visually explain how to assemble an FH7690 cube featuring the FH7690 extrusion, FH762 extrusion and FH7690 End Plate.  It reviews the components needed and the steps taken to create a cube.  It even shows how fabric is inserted into the channels and also shows some design ideas.

When constructing a display or tradeshow booth, the FH7690 End Plate is installed into the top and bottom of the FH7690 vertical extrusion posts using a countersunk screw inserted into its custom insert block.  After this, the FH762 horizontal extrusions can be connected to the FH7690 verticals by tightening their CBX connectors with a hex key. The result is an end plate that not only covers the ends of the FH7690, but also acts as a symmetrical point of convergence for 8 different fabric channels. This creates continuous channels in which SEG Fabric can be inserted, allowing designers to create seamless fabric cubes without having to “jump” fabric around inside and outside corners.

In addition to fabric cubes, this new FH7690 End Plate can be used to create entire rooms of seamless SEG fabric due to its inside corner fabric channels.

Raising The Bar


This past December AGAM received a game changing piece of machinery which takes our already industry-leading custom capabilities to another level. With 4 controlled axes, our new Aluminum Machining Center becomes a versatile tool in manufacturing custom displays that make the ultimate statement.

The Aluminum Machining Center allows AGAM’s extensive line of profiles to be customized with extreme precision and efficiency. What makes the machine unique from others that we own is the continuous rotating work table that allows machining from -90° to +90° on extrusions up to 120” in length!



The Aluminum Machining Center makes quick work of custom slots:


Precision milling long lengths of aluminum is no problem:


In addition to milling custom slots and holes in our profiles; this machine allows us to think outside the box and discover solutions to problems once thought to be impossible. We are able to program the Aluminum Machining Center to do complex operations such as grudging our 108mm (4 ¼”) round VR108 profile and the results are top-notch!


The following is the video of the Aluminum Machining Center machining the VR108 profile, demonstrating its precision and efficiency. *Please note that the machining portion of the video has been increased by 4x to keep the video short.

To learn more about this exciting new machine and what it can do for you, please contact your AGAM representative today!

FH Curved Plate

As a designer at AGAM, I get to see firsthand design trends and must “invent” and engineer solutions to meet those client demands. Over the past few years, SEG (silicone edge graphics) or fabric graphics have exploded in popularity because of their versatility, ease of assembly, and packing/shipping efficiency.

Recently, more and more designs are requesting tightly curved fabric corners (radius ≤ 6”) and I have now developed a viable solution: the FH Curved Plate.

FH108 Curved Plate_3

AGAM’s latest product and addition to the FH series opens up many new design possibilities. The FH Curved Plate provides a simple, yet extremely effective way to create tight rounded corners on previously non-bendable extrusions. It is compatible with the FH761, FH762, FH1081, and FH1082. Fabricated from a series of stacked aluminum plates, the FH Curved Plate is lightweight and easy to assemble. It simply slides into the corresponding extrusion and is secured using two small screws. Looking at the exterior of the frame, the connection appear almost seamless with no fasteners or holes visible.

Here is a step-by-step process showing how FH Curved Plate is assembled:

(2) FH108 Curved Corner_Sample Pictures-6

(3) FH108 Curved Corner_Sample Pictures-4

(4) FH108 Curved Corner_Sample Pictures-2

(5) FH108 Curved Corner_Sample Pictures-1

I tested an actual frame with a graphic installed to make sure the concept was viable. We quickly learned that although the curved plate did its job well at the top and bottom of the frame, the SEG still needed support running the entire length of curve to keep a consistent radius. To solve this problem, we simply installed an oversized piece of sintra, matching the curve of the plate to “push out” the fabric. Below are photos of the final result:

(6) _DSC4388

(7) _DSC4390

(8) _DSC4396

I can also customize the engineering and fabrication of this new product. Both the radius and angle of the plate can be changed based on design specifications. We are not limited to a standard 90 degree angle; we can do nearly anything from 0 to 180 degrees is possible. The FH Curved Plate can make custom-angled banners, S-curves, waves, etc. As with almost all of our products, it can be powder coated in any custom color to create a truly seamless look. The possibilities are limited only by the designer’s imagination.

Let me know if you would like to receive more information about this product line. I can also help with the engineering of your design(s). My email address is

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