Looking for a rigid yet lightweight sheet material

[dynamicgrange]

Bit of an unusual request, I know...

I'm looking for a sheet material which will be sized 170cm x 90cm and will be supported horizontally/flat on both short sides. It must be rigid (no sagging or risk of breaking) and also fairly lightweight.

I've tried 12mm MDF which is pretty good but sags slightly and before I continue the project I want to see if there's a better solution.

It will be covered in fabric so the look isn't important, but I will need to be able to drill many small 1.5mm holes through it.

Thanks!

 

[Burnerman]

Plywood or OSB is stronger than MDF by far - but any sheet material is going to distort to some degree.
Can you have a supporting frame underneath.....timber or steel - to aid support?
John

 

[big-all]

what load is it going to have on it ??
4x1" planed [94x19mm] may do or 89x38 cls
ahh ok scrub that scaffold boards 227mm x 3 or 4

 

[dynamicgrange]

Thanks - it is for ceiling panels with fibre optics so cannot be supported from underneath. There'll be no weight on them apart from the fabric and some fibre optic strands

 

[Burnerman]

One of the best sheet materials to resist bending is block board, not so readily available as it once was.
Thicknesses today are usually 18mm but 22 and 25 are available away from the diy sheds.
How about a beech solid worktop offcut?
John

 

[big-all]

thinking outside the [egg]box
2x hollow cupboard door cut to size and re edged or a normal flush door cut in half with added edging
https://www.diy.com/search?term=900+mm+cupboard+door
https://www.diy.com/departments/4-p...h-internal-door-h-1981mm-w-838mm/42655_BQ.prd

 

[Deleted member 174758]

We often make up 595 x 595mm patresses for the electricians to sit above suspended (false) ceiling panels supporting lighting, sensors (movement, PIR lighting control intruder alarm, temperature, etc) , sounders (alarms), etc. Depending what is being supported these are made from 6, 9, 12, 15 or 18mm hardwood plywood although the heavier ones often require additional support from the ceiling above (using small diameter braided steel cables, Gripples, etc). Plywood is fairly rigid, takes screws well and has a good load carrying capacity

 

[crank39]

How about this...

https://www.ebay.co.uk/itm/201522905636

Comes in 8x4 sheets

 

[Tigercubrider]

What is the distribution pattern on the holes?
A thin sheet could have ribs glued at 90° to the horizontal to create a honeycomb effect.
Or screw through the sheet (missing your hole pattern) to a batten, using short lengths of narrow bore pipe as spacers so you have ribs - also possibly useful to hold the fibres in place

 

[^woody^]

Cement board (calcium silicate or magnesium oxide) such as Masterboard, Hardybacker or Supalux.

 

[crank39]

Or even 25mm kingspan/celotex

 

[foxhole]

Plasterboard, designed for the job.

 

[freddiemercurystwin]

Thanks - it is for ceiling panels with fibre optics so cannot be supported from underneath. There'll be no weight on them apart from the fabric and some fibre optic strands

Why not speak some of the suppliers for these to see what their panels are made from?

 

[^woody^]

Oh I see its cm not mm

Anyway, when suspended ceilings are done, the intermediate areas are suspended off wire/cable, so I suspect you will need to do the same and fix some brackets at various points and attach the other end to the structural ceiling. In this case you can use any material even MDF, and the bracket fixings will be hidden on the underside by the fabric.

 

[dynamicgrange]

Thanks all - Pre-made panels are generally 1m2 so less prone to sagging. My setup is slightly different so I require longer panels and I do not wish to have fixings visible.

I'll have a look into each of the suggestions!