Here are some specifics about the manufacturing and processing of handcrafted metal hardware.
- Mold Production
After creating the product renderings in accordance with the customer’s original sketches, specifications, or samples and receiving the customer’s approval, the manufacturing order will be officially placed. The next steps are the following ;
- Numerical Control Programming
- Complete Engraving By Digital Control Machine
- Heat Treatment
- Wire Cutting
- Composite Mold
- Die Casting Mold
The mold additionally requires a mold base, a mold core, a feeding device, and a parts ejector in addition to itself. Other names for these manipulators are typically created as general-purpose or computer-controlled.
2. Stamping Process
Stamping production uses presses, hydraulic presses, forging presses, and dies to exert external force on plates and strips to generate semi-finished items of the intended size and shape (copper sheets, brass sheets, cold rolled iron sheets, aluminum sheets). The initial step in the process flow is stamping the finished product. The size must be precise, and the lines, characters, and patterns must be complete and legible.
3. Die Casting
In the process of die-casting, molten metal is poured into a mold at a high rate of speed and pressure, where it crystallizes and solidifies to produce a product. The three components of a die-casting machine, a die-casting mold, and zinc alloy are organically merged and utilized in full during the die-casting process. Coordinating process variables like pressure, speed, temperature, and time, as well as the choice of premium materials and the design of cutting-edge molds, is required to produce items of a high caliber. Die-casting items must have lines, letters, and patterns, as well as be complete and clear, exact in size, and free of watermarks.
4. Laser Cutting
Laser cutting irradiates the workpiece with a focused, high-power density laser beam in order to make the cutout in the product. A final outcome of this is that the substance melts, ablates, or ignites very quickly. A high-speed airflow that is coaxial with the beam is also sweeping the radiation-damaged material away at the same time.
5. Welding And Pot Pins
All badges are designed to be worn with welding pins or pot pins, and solder pins are broken down into glue dipping, fire soldering, tin soldering, silver soldering, brazing, and tin soldering categories. In order to create the pot needle, a drill press mold is used to cast the needle pot onto the badge.
Polishing is the process of brightening a product’s surface using machinery, a polishing wheel, and polishing wax. There are multiple polishing waxes used mostly for products composed of various components (sand, soft, hard, hemp wheels, soft and hard cloth wheels). The finished product should not only be glossy but also free of pitting and deformities.
The method of electroplating involves coating the product’s surface with a layer of metal that the customer specifies using the electrolysis concept. During electroplating, the product to be plated is used as the cathode, the coating metal and insoluble solution is used as the anode, and the coating metal’s cations are deposited on the product’s surface to form a coating. This coating makes the product more attractive and brilliant, improves its wear resistance, and stops it from oxidizing. Products that have undergone electroplating must be free of pits and bubbles.
After degreasing, repainting, phosphating, drying, and painting in accordance with the color and product quality desired by the customer, the products to be painted are painted using a spray painting technique. Spray the primer first, let it dry, then spray the topcoat and bake it till it is completely dry.
The most crucial step in handicraft production is coloring, which also has the greatest impact on a product’s quality.
- Then they are each given a different amount of colorful metal oxides, roasted, and ground into powder. When using, choose the enamel powder based on the unique color card, grind it, wash it in pure water, dry it with a flat-headed iron needle on the cleaned bottom tire, and then sinter it at high temperatures. After cooling, add water, sulfuric acid, dry, and a new color; next, sinter. Once all the colors have been sintered, the product is repaired by beginning to grind the stone, first coarsely and then finely. The smoothness and brightness of the enamel surface are determined by the final firing.
- Epoxy resin and color powder are used to grind fake enamel color paste. When using, tone according to the color card, add the appropriate amount of hardener, dry with a syringe on the cleaned and heated bottom tire, and then add another color.
- The objects that have been electroplated are colored during the baking paint process. In order to prevent the product’s color from changing for a very long time, we chose acrylic high-temperature paint for the paint. Apply the coloring on the product using a syringe after coloring. There are coloring machines available right now that might be used for large orders. Typically, after applying color, wipe it away with a clean towel.
- Is primarily used for badges and work number plates that customers request in certain colors and basic patterns. The needle and anti-burr with glue are typically coated after the printed badge has been punched out.
- The majority of scenic badges with intricate patterns, numerous hues, and gradient colors are best printed using lithography.
- When making a badge, the designed artwork is first put on a film negative. After the printing is exposed, the artwork is transferred to a copper plate, and the pattern is then etched with chemicals in a specific machine.
10. Silk Screen Processing
In contrast to silk-screen badges, silk-screen processing involves overprinting lettering or patterns on false enamel, flat metal, or bonded surfaces.
Packing a product must be done in accordance with the demands of the buyer. A paper card should be placed in a plastic bag or a bubble bag before being packed into a middle box or bag. The outside box should then be filled and taped.
12. Quality Assurance
A quality inspection department must be set up to guarantee the quality of products. A full-time quality supervisor oversees the daily operations of each workshop at the Foison Metal facility and is in charge of verifying the initial product. Complete examination of all goods produced in the workshop, including stamping, die casting, polishing, electroplating, and packaging. To verify the quality of the provided items, inspection of each individual product as well as sampling inspection of final products after packaging.
Manufacturing sheets, quality control sheets, initial item confirmation sheets, inspection record sheets, electroplating product inspection sheets, finished product inspection sheets, and qualified product identification, all part of the rigid production process flow that Relia Metal adheres to.