Category: Case Study

At AFAC, we pride ourselves on delivering custom solutions tailored to the unique needs of our clients. Recently, we had the opportunity to work with a prominent lighting manufacturer who required a bespoke part for their production line. This case study highlights our process, the challenges we faced, and the ultimate success of the project.

The Challenge

Our client, a leader in the lighting industry, approached us with a specific requirement for a blanking plug. This part needed to fit a particularly large hole in their assembly. The blanking plug also had to withstand high temperatures, as it would be exposed to powder-coating ovens during the manufacturing process. The client emphasized the need for a reliable seal around the edge of the hole and an easy method for removal.

Our Solution

Understanding the critical nature of this component, our team at AFAC designed a custom blanking plug made from high-quality silicone rubber. Here’s how we addressed the client’s requirements:

1. Precision Fit: We engineered the blanking plug to fit perfectly into the specified hole. The seals were designed to ensure a tight, reliable fit around the edge, preventing any leaks or gaps.
2. High-Temperature Resistance: The silicone rubber used in the plug is capable of withstanding temperatures up to 260 degrees centigrade. This ensures that the plug can safely go through the powder-coating ovens without degrading or losing its integrity.
3. Ease of Use: We included a small handle on the plug, allowing for easy insertion and removal. This feature was particularly important for the client’s production team, as it streamlined their assembly process and reduced downtime.

The Results

Our custom blanking plug proved to be a perfect fit for the client’s needs. The precision of the seals and the high-temperature resistance of the silicone rubber ensured that the plug performed flawlessly in the production environment. The ease of use also received positive feedback from the client’s production team.

Client Feedback

The client was highly satisfied with the solution we provided. They praised the quality and durability of the blanking plug, noting that it significantly improved their production efficiency. The success of this project has strengthened our relationship with the client, and we look forward to collaborating on future projects.

Conclusion

This case study exemplifies AFAC’s commitment to providing tailored solutions that meet the specific needs of our clients. By understanding the challenges faced by our customers and leveraging our expertise in custom parts manufacturing, we deliver products that enhance production processes and contribute to the success of our clients.

If you are a quality manager, production manager, or product designer looking for custom parts to optimise your manufacturing process, AFAC is here to help. Contact us today to discuss your requirements and discover how we can support your business.

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For more information on our custom manufacturing capabilities, please complete the form below or contact our team directly on 0345 094 0993. We are always ready to assist you with your specific needs.

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Welcome to AFAC! Today, I’d like to introduce you to some of our custom silicone rubber mouldings. Each of these mouldings has been designed to meet specific needs for our diverse range of customers. Let’s take a closer look at a few examples to showcase the versatility and precision of our work.

Unique Custom Mouldings for Varied Applications

Awkward-Shaped Item with Electrical Contact

One of our projects involved creating a moulding for an unusually shaped item. This component had a flat-sided slot on one side and a hole on the other. Additionally, the outside of the part required plating. To meet these requirements, we designed a moulding that allowed for a wire to pass through the middle, providing an electrical contact while accommodating the complex shape.

Industrial Nozzle for Fluid Injection

For another customer, we developed a silicone rubber nozzle used in an industrial application for injecting a product. The end of this nozzle is cut to allow fluid to pass through, similar to how a silicone tube might be used in domestic settings, but built to withstand the rigours of an industrial environment.

Masking Plug for Production Lines

Another innovative solution was for a customer struggling to centre self-adhesive masks on a fast-paced production line. We designed a masking plug that filled the hole perfectly and ensured precise centring every time, significantly improving efficiency and accuracy in their process.

Simple Blanking Plug

We also produce simple blanking plugs. One of these was specifically designed to prevent dust and other contaminants from entering a hole in an assembly. This particular plug wasn’t for masking purposes but purely to keep the assembly clean and functional.

Electroplating Mask with Tapered Edge

In another application, we developed a silicone rubber mask for an electroplating process. The large assembly required a band around it to be protected from plating. Our solution featured a tapered edge to ensure the band was effectively masked throughout the process, protecting the integrity of the part during plating.

Conclusion

These examples illustrate the wide variety of custom silicone rubber mouldings we produce at AFAC. Each moulding is designed to solve specific challenges, whether it’s for masking, fluid injection, or simply protecting parts from contamination. With over 40 years of experience, we pride ourselves on our ability to deliver bespoke solutions tailored to the unique needs of our customers.

If you are a quality manager, production manager, or product designer seeking custom silicone rubber mouldings for your applications, AFAC is here to help. Contact us today to discuss your requirements and discover how we can enhance your production process with our custom solutions.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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AFAC excels in meeting the specialised needs of industries where precision and reliability are paramount. This case study details our collaboration with a leading subcontract manufacturer of precision castings in the defence sector. The project involved creating custom-cut masking tape tailored to their specific requirements.

The Challenge

The client, a renowned manufacturer in the defence sector, approached AFAC with a unique challenge. They required custom-cut masking tape for use in the production of precision castings. These tapes needed to withstand high temperatures and be cut to very specific shapes to match their intricate casting moulds.

Our Solution

At AFAC, we understand the critical nature of products used in the defence sector and the importance of adhering to exact specifications. Here’s how we approached the client’s needs:

1. Material Selection: We chose high-grade polyester tape capable of withstanding temperatures up to 220 degrees Celsius, ensuring that it would perform reliably in the demanding environments of casting and moulding processes.
2. Precision Cutting: Utilising state-of-the-art cutting technology, we produced tapes cut to the exact specifications required by the client. This precision ensured a perfect fit for their moulds, aiding in the production of high-quality precision castings.
3. Packaging and Delivery: To facilitate ease of use in the client’s production lines, we provided the custom-cut tapes on rolls and in kits. This packaging solution helped streamline their manufacturing process, reducing setup time and increasing overall efficiency.

The Results

The custom-cut masking tapes were implemented successfully in the client’s production processes. The precision of the cuts and the high-temperature resistance of the material met all the rigorous demands of their manufacturing environment.

Client Feedback

The client reported significant improvements in their production efficiency and a reduction in waste, attributing these gains to the bespoke design and quality of the masking tapes provided by AFAC. The ability to withstand high temperatures without degradation during the casting process was particularly praised.

Conclusion

This project highlights AFAC’s capability to design and manufacture custom solutions that meet the exacting standards of the defence sector. Our commitment to quality and precision in manufacturing custom parts ensures that we can meet the specific needs of any industry, particularly where superior performance under challenging conditions is required.

If you are a quality manager, production manager, or product designer in need of custom parts that meet high standards of precision and reliability, AFAC is here to help. Contact us to discuss how we can assist in enhancing your manufacturing processes with our bespoke solutions.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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At AFAC, our expertise in silicone rubber mouldings allows us to cater to a wide range of industrial needs. A prime example of our capability is the custom-made silicone rubber plugs we recently designed for a client in the pumps and filters sector.

The Product

The silicone rubber plugs were specifically engineered to address a unique challenge: masking an area around a hole while also covering a hexagonal bolt (referred to here as a “Hexer”) that protrudes slightly from the surface. The design features a deeper recess, tailored to accommodate and completely cover the bolt, ensuring a snug fit and optimal masking during manufacturing processes.

Key Features

• Deeper Recess: Allows the plug to accommodate protrusions such as bolts or screws, providing a seamless cover.
• Convenient Handle: Integrated at the top for easy insertion and removal, enhancing user convenience and efficiency in high-paced industrial settings.
• Tail Design: A slight tail at the end of the plug not only helps in pulling it to ensure a tight fit but also aids in its removal, making the process smoother and faster.

The Impact

These custom-designed plugs significantly improved the client’s production process by providing an effective solution for a complex problem. The precise fit and the ability to withstand industrial conditions meant that our client could rely on these plugs to perform consistently, reducing downtime and increasing overall efficiency.

Conclusion

This project exemplifies AFAC’s dedication to innovation and quality in the production of custom silicone rubber mouldings and plugs. We understand that each industry has unique needs, and our goal is to provide bespoke solutions that enhance production capabilities and achieve high levels of satisfaction.

Whether you’re in the pumps and filters market or any other industrial sector, AFAC has the expertise to deliver custom solutions tailored to your specific requirements. Get in touch with us today to see how we can assist in enhancing your production process with our custom silicone rubber products.

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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Introduction

Welcome to the AFAC Custom Masking Program! Today, we are excited to present a unique solution designed to meet the specific needs of one of our customers. This case study highlights the development and application of a custom large silicone rubber band used for masking a band around a cylindrical object during the electroplating process.

The Challenge

Our client, a manufacturer in the electroplating industry, faced a challenge in achieving a precise and liquid-tight seal around cylindrical objects during plating. The existing solutions often allowed plating solutions to seep underneath the masks, resulting in imperfect finishes and increased rework, leading to higher production costs.

Our Solution

To address this issue, AFAC designed a custom large silicone rubber band with the following features:

1. Elasticity for a Snug Fit: The silicone rubber band is highly elastic, ensuring a snug fit around the cylindrical objects. This elasticity makes the band easy to install and remove, improving the efficiency of the masking process.
2. Chamfered Edges: The band features chamfers on either side, which provide a liquid-tight seal. These chamfers are crucial in preventing plating solutions from seeping underneath, ensuring a clean and precise finish.
3. Durability and Reusability: Made from high-quality silicone, the band is durable and can be reused multiple times without losing its elasticity or effectiveness, further reducing costs for the client.

Implementation and Results

The custom silicone rubber band was integrated into the client’s electroplating process with significant success. Here’s how it made an impact:

• Precision Plating: The chamfered edges ensured that the plating solution did not seep under the mask, resulting in a precise and consistent plating finish.
• Reduced Rework: The improved sealing and precision reduced the need for rework, lowering production costs and increasing throughput.
• Ease of Use: The elastic nature of the band made it easy for workers to install and remove, speeding up the masking process and enhancing overall productivity.
• Cost Efficiency: The durability and reusability of the silicone bands provided long-term cost savings, making the solution both effective and economical.

Client Feedback

The client expressed high satisfaction with the custom solution provided by AFAC. They noted the significant improvement in the quality of their electroplating finishes and the reduction in production costs due to decreased rework and enhanced efficiency. The ease of use and durability of the bands were also highlighted as major benefits.

Conclusion

This case study demonstrates AFAC’s commitment to providing tailored solutions that address specific manufacturing challenges. By designing a custom silicone rubber band with precise features, we were able to help our client achieve higher accuracy and efficiency in their electroplating process.

If you are a quality manager, production manager, or product designer looking for custom masking solutions to enhance your manufacturing processes, AFAC is here to help. Contact us today to discuss your requirements and discover how our innovative solutions can support your production goals.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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Welcome to AFAC Custom Moulding Division! Today, we are excited to present an innovative oval-shaped plug designed for a defence application. This case study highlights the creation and long-term success of a custom solution developed to address the specific needs of masking electrical contacts during powder coating or high-temperature metal finishing.

The Challenge

Over 25 years ago, our client in the defence sector faced a significant challenge: effectively masking an oval slot hole and its surrounding area during the powder coating process. The primary issue was ensuring a perfect seal to prevent powder from creeping under the plug, which could compromise the integrity of the electrical contacts and the overall quality of the finished product.

Our Solution

AFAC developed a custom oval-shaped plug specifically designed to address this challenge. Here are the key features of our solution:

1. Oval Shape: The unique oval shape of the plug was tailored to fit the specific dimensions of the slot hole, ensuring comprehensive coverage.
2. Protective Ring: The plug features a protective ring around its base, providing a perfect seal and preventing any powder from seeping underneath during the coating process.
3. High-Temperature Resistance: Made from durable materials, the plug can withstand the high temperatures involved in powder coating and metal finishing processes, ensuring reliable performance and longevity.

Implementation and Results

The custom oval-shaped plug was integrated into the client’s manufacturing process and has been a crucial part of their production ever since. Here’s how it made an impact:

• Effective Masking: The plug provided an effective solution for masking the oval slot hole and its surrounding area, ensuring that the electrical contacts remained free from powder.
• Perfect Seal: The protective ring feature ensured a liquid-tight seal, maintaining the integrity of the masking and preventing any powder from creeping under the plug.
• Durability and Reliability: The high-temperature resistance of the plug ensured that it could withstand repeated use in the demanding conditions of the client’s manufacturing process, providing long-term reliability and performance.

Client Feedback

The client has continued to use the custom oval-shaped plug for over 25 years, a testament to its effectiveness and durability. They have praised the plug’s ability to provide a perfect seal and maintain the quality of their finished products. The consistent performance of the plug has made it an indispensable part of their production process.

Conclusion

This case study highlights AFAC’s expertise in developing long-lasting, effective custom solutions for challenging industrial applications. The innovative oval-shaped plug designed for the defence sector demonstrates our commitment to addressing specific customer needs and ensuring high-quality results.

If you are a quality manager, production manager, or product designer looking for custom masking solutions that meet precise requirements, AFAC is here to help. Contact us today to discuss your needs and discover how our bespoke products can enhance your manufacturing processes.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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Welcome to AFAC Custom Masking Division! Today, we are excited to showcase an innovative plug designed to solve a specific masking challenge faced by one of our customers. This case study highlights how our tailored solution improved their production efficiency, precision, and cost-effectiveness.

The Challenge

The client, a manufacturer struggling with centering self-adhesive dots around holes during production, needed a more reliable and efficient masking solution. The primary issues were difficulty in achieving precise placement and the inefficiency of using self-adhesive dots, which often led to production delays and increased costs.

Our Solution

To address these challenges, AFAC designed a custom plug with the following key features:

1. Comprehensive Masking: The plug effectively masks not only the hole but also the surrounding area, providing a more thorough solution than self-adhesive dots.
2. Hollowed Back Design: The plug features a hollowed back, which reduces the amount of silicone used in its production, thereby cutting costs while maintaining functionality.
3. Small Handle for Easy Removal: A small handle is incorporated into the design, ensuring that the plug can be easily inserted and removed, streamlining the masking process.

Implementation and Results

The custom plug was integrated into the client’s production line, leading to significant improvements:

• Enhanced Efficiency: The easy-to-use design allowed for quick and accurate placement, reducing production time and increasing throughput.
• Increased Precision: By masking both the hole and the surrounding area, the plug ensured precise coverage, improving the quality of the final product.
• Cost-Effectiveness: The hollowed back design reduced material costs, and the reusable nature of the plug further contributed to long-term savings.

Client Feedback

The client was extremely satisfied with the custom masking plug. They noted the substantial improvement in production efficiency and precision, as well as the cost savings achieved through reduced material usage and increased reusability. The ease of removal and placement was particularly praised for simplifying their workflow.

Conclusion

This case study exemplifies AFAC’s commitment to developing innovative and cost-effective solutions tailored to our clients’ specific needs. By addressing the challenges faced by the manufacturer, our custom plug enhanced their production processes and overall product quality.

If you are a quality manager, production manager, or product designer seeking custom masking solutions to optimise your manufacturing processes, AFAC is here to help. Contact us today to discuss your requirements and discover how our bespoke products can enhance your operations.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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Welcome to another case study with AFAC Custom Masking Solutions. Today, we are excited to highlight a specially developed pull plug designed for a European wheel manufacturer. This case study focuses on the application and benefits of this custom solution in the manufacturing of wheels for large vehicles.

The Challenge

The client, a prominent European manufacturer of alloy and steel wheels for large vehicles, faced a critical challenge in their powder-coating process. Ensuring a powder-free chamfer on the wheels was essential for safety, as it allowed for accurate metal-to-metal contact when bolts were torqued. Any powder build-up on the chamfer could lead to powder cracking, resulting in inaccurate torque settings and potential wheel failure, posing significant safety risks.

Our Solution

To address this issue, AFAC developed a custom pull plug specifically designed to protect the chamfer on alloy and steel wheels during the powder-coating process. Here are the key features of our solution:

1. Effective Protection: The pull plug provides robust protection for the chamfer, preventing any powder build-up during the coating process.
2. Ease of Use: Designed for easy installation and removal, the pull plug ensures a seamless fit, which enhances efficiency on the production line.
3. Durability: Made from high-quality materials, the pull plug is durable and withstands the rigorous conditions of the manufacturing environment, ensuring long-term usability.

Implementation and Results

The custom pull plug was successfully integrated into the client’s manufacturing process, yielding significant improvements in safety and efficiency. Here’s how it impacted their operations:

• Safety Enhancement: By preventing powder build-up on the chamfer, the pull plug ensured accurate metal-to-metal contact, eliminating the risk of powder cracking and potential wheel failure.
• Reliability: The precise protection provided by the pull plug contributed to more reliable torque settings, enhancing the overall safety of the wheels.
• Efficiency: The easy-to-use design of the pull plug streamlined the production process, reducing downtime and increasing throughput.

Client Feedback

The client was highly satisfied with the custom pull plug solution provided by AFAC. They appreciated the significant improvement in the safety and reliability of their wheels. The efficiency gains in their production process were also noted as a major benefit, as it allowed for smoother operations and reduced potential for error.

Conclusion

This case study showcases AFAC’s commitment to developing custom solutions that address specific challenges in manufacturing processes. By designing a pull plug that effectively protects the chamfer on wheels, we were able to enhance both safety and reliability for our client in the heavy machinery sector.

If you are a quality manager, production manager, or product designer looking for custom masking solutions to improve your manufacturing processes, AFAC is here to help. Contact us today to discuss your requirements and discover how our innovative solutions can support your production goals.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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Welcome to AFAC Custom Masking Division! Today, we are highlighting a successful application of our self-adhesive masking solutions for a customer who designs and manufactures waterproof instrument bodies. This case study showcases how our self-adhesive masks and complementary plugs have streamlined their production process, providing flexibility and efficiency.

The Challenge

Our customer needed a reliable masking solution to ensure that specific areas of their waterproof instrument bodies remained clear during the powder coating process. This requirement was crucial to maintain the integrity and functionality of the instruments. Additionally, they sought a solution that offered flexibility to accommodate design changes and new trials without relying on external suppliers.

Our Solution

AFAC provided a comprehensive self-adhesive masking solution tailored to the customer’s needs:

1. Red Self-Adhesive Masks: These masks are designed to withstand the powder coating process while ensuring precise coverage of the designated areas. The high-quality adhesive ensures they stay in place, preventing any coating from reaching the masked sections.
2. Complementary Plugs: Plugs are used at both ends of the instrument bodies, providing complete protection and ensuring no powder infiltration during the coating process.
3. Self-Adhesive Material on Rolls: The customer opted to purchase self-adhesive material on rolls, allowing them to cut shapes internally. This approach provides significant flexibility, enabling them to adapt quickly to design changes and conduct new trials without waiting for externally sourced materials.

Implementation and Results

The implementation of AFAC’s self-adhesive masking solution led to several positive outcomes for the customer:

• Streamlined Production Process: The use of red self-adhesive masks and complementary plugs simplified the masking process, reducing preparation time and increasing overall efficiency.
• Flexibility and Adaptability: By cutting their own shapes from self-adhesive material rolls, the customer could easily accommodate design modifications and experimental trials. This flexibility reduced downtime and accelerated the development cycle.
• Enhanced Product Quality: The precise masking ensured that critical areas remained clear during powder coating, maintaining the waterproof integrity and high quality of the instrument bodies.

Client Feedback

The customer expressed great satisfaction with the self-adhesive masking solution provided by AFAC. They highlighted the significant improvements in their production workflow and the enhanced ability to adapt to design changes swiftly. The reliability of the masks and plugs during the powder coating process was particularly appreciated, as it ensured consistent product quality.

Conclusion

This case study demonstrates AFAC’s commitment to delivering innovative and flexible masking solutions tailored to meet specific customer needs. By providing high-quality self-adhesive masks and complementary plugs, we helped our client streamline their production process and maintain the high standards required for waterproof instrument bodies.

If you are a quality manager, production manager, or product designer seeking adaptable and efficient masking solutions for your manufacturing processes, AFAC is here to assist. Contact us today to discuss your requirements and discover how our tailored products can enhance your operations.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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