Category: Manufacturing

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Masking irregular shaped parts during metal finishing

Masking Irregular Shapes during metal finishing

Masking plays a crucial role in metal finishing, especially for irregular-shaped parts. It involves covering specific areas of a part to prevent them from being exposed to the finishing process. Masking is important for two main reasons:

Protecting Specific Areas

During metal finishing, some areas of a part may need to be protected from the process. For example, threaded holes, mating surfaces, or bearing surfaces may need to be kept free of any coating or plating. Masking ensures these areas remain unaltered during the finishing process.

Ensuring Consistent Finishing

Masking also helps achieve a consistent and uniform finish on the surface of a part. By protecting specific areas, the finishing process can be applied evenly, resulting in a high-quality final product.

Types of Masking Techniques

There are several masking techniques available, each with its own set of advantages and disadvantages. The most common techniques include tape masking, and custom masking solutions.

Tape Masking

Tape masking involves using adhesive tapes to cover the areas of a part that need to be protected. These tapes are specifically designed for masking purposes and can withstand the chemicals and temperatures involved in metal finishing processes.

Advantages of Tape Masking

  1. Easy to apply and remove, making it suitable for small-scale production or prototypes.
  2. Provides a reliable seal when applied correctly.

Disadvantages of Tape Masking

  1. Can be challenging to apply on irregular or complex shapes.
  2. May not provide a tight seal on parts with sharp edges or tight corners.

Custom Masking Solutions

Custom masking solutions involve designing and manufacturing masks specifically for a particular part or application. These masks can be made from various materials, such as silicone, rubber, or metal, and are designed to fit the part precisely.

Advantages of Custom Masking Solutions

  1. Provides the best fit and seal for irregular-shaped parts.
  2. Can be more efficient for high-volume production.

Disadvantages of Custom Masking Solutions

  1. Higher initial cost due to the design and production of custom masks.
  2. Longer lead times for mask production.

Selecting the Right Masking Technique for Irregular-Shaped Parts

To choose the best masking technique for irregular-shaped parts, several factors need to be considered.

Masking irregular shaped parts: Factors to Consider

Shape and Size of the Part

Complex shapes, tight corners, and intricate features may require custom masking solutions for the best fit and protection. In contrast, simpler parts with fewer geometric complexities may be suitable for liquid or tape masking.

Metal Finishing Process

The specific metal finishing process being used can influence the choice of masking technique. For instance, some processes may require higher temperature resistance, necessitating the use of specialized masking materials.

Production Volume

The volume of parts being processed can also impact the choice of masking technique. For high-volume production, custom masking solutions may be more efficient and cost-effective in the long run. However, for low-volume production or prototyping, liquid or tape masking may be more appropriate.

Tips for Effective Masking of Irregular Shaped Parts

  1. Carefully assess the part’s geometry to determine the best masking technique.
  2. Test the masking materials to ensure they can withstand the chemicals and temperatures involved in the metal finishing process.
  3. Make sure the mask is applied and removed carefully to prevent damage to the part or the mask itself.
  4. Inspect the parts after the finishing process to ensure the masked areas are free of any residue or damage.

Conclusion

Masking is a crucial aspect of metal finishing, especially for irregular-shaped parts. By selecting the right masking technique and following best practices, manufacturers can achieve a consistent, high-quality finish on their products while protecting critical areas from the finishing process. The choice between liquid masking, tape masking, and custom masking solutions depends on factors such as part geometry, the specific finishing process, and production volume.

FAQs

  1. What is the purpose of masking in metal finishing? Masking protects specific areas of a part from being exposed to the finishing process, ensuring a consistent and uniform finish.
  2. What are the common masking techniques used in metal finishing? The most common masking techniques include liquid masking, tape masking, and custom masking solutions.
  3. How do I choose the best masking technique for my irregular-shaped parts? Consider factors such as part shape and size, the metal finishing process being used, and production volume to determine the best masking technique for your specific application.
  4. Are there any disadvantages to using custom masking solutions? Custom masking solutions can have higher initial costs due to the design and production of custom masks, as well as longer lead times for mask production. However, they often provide the best fit and protection for irregular-shaped parts.
  5. Can masking materials be reused? Some masking materials, such as custom masks made from silicone or metal, can be reused multiple times if they are properly cared for and not damaged during the finishing process. However, liquid masking and tape masking materials are typically single-use.
  6. How can I ensure that the masked areas are properly protected during the metal finishing process?To ensure the masked areas are well-protected, follow these steps: a. Choose the appropriate masking technique and material based on the part’s geometry and the specific finishing process. b. Properly clean and prepare the part’s surface before applying the mask. c. Apply the mask with care, ensuring a tight seal and full coverage of the areas to be protected. d. Inspect the masked parts before and after the finishing process to ensure that the masking material has remained intact and the protected areas are free from residue or damage.
  7. How does the choice of masking technique affect the overall cost of metal finishing?The choice of masking technique can impact the overall cost of metal finishing in several ways. While custom masking solutions may have higher initial costs due to design and production, they can offer long-term cost savings through increased efficiency and reduced rework for high-volume production. On the other hand, liquid and tape masking techniques may be more cost-effective for small-scale production or prototyping, but they can be time-consuming and less reliable for complex or irregular-shaped parts.
  8. What factors should be considered when choosing a masking material?When selecting a masking material, consider the following factors: a. Compatibility with the specific metal finishing process, including resistance to chemicals and temperatures involved. b. Ease of application and removal. c. Ability to conform to complex or irregular shapes. d. Reusability, if applicable.
  9. How can I ensure that the masking material does not damage the part during the metal finishing process?To prevent damage to the part during the metal finishing process, make sure to: a. Choose the appropriate masking material that is compatible with the specific finishing process. b. Properly clean and prepare the part’s surface before applying the mask. c. Apply the mask carefully, avoiding excessive pressure or stretching that could cause damage. d. Remove the mask gently after the finishing process, following the manufacturer’s guidelines for removal.
  10. Is it possible to automate the masking process for irregular-shaped parts?
    Automating the masking process for irregular-shaped parts can be challenging due to the complex geometry of the parts. However, some advanced automation systems, such as robotic arms with machine vision, can be used to apply masks with high precision. The choice of masking technique and material, as well as the specific requirements of the metal finishing process, will influence the feasibility and cost-effectiveness of automation for masking irregular-shaped parts.
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Die-Cut Self Adhesive Shapes for Masking

Die Cut Self Adhesive

In today’s world, with a growing emphasis on hygiene and cleanliness, there is an increasing demand for products that offer protection against germs and contamination. One such product is custom die-cut self-adhesive shapes that are specifically designed for masking and protection. In this article, we will discuss what custom shapes are, their benefits, and how they can be used in various industries.

What are Custom Die-Cut Self Adhesive Shapes?

Custom die-cut self-adhesive shapes are precision-cut pieces of material that are designed to fit specific applications. They are made from a range of materials, including paper, vinyl, and polyester, and can be cut into any shape or size to fit a specific product or application.

These shapes are produced using a process called die-cutting, which involves using a machine to cut a shape out of a material. The machine uses a sharp blade, or “die,” to cut the material to the desired shape. The process is highly precise, and the shapes produced are consistent in size and shape, making them ideal for applications that require high levels of accuracy.

Benefits of Custom Die Cut Self Adhesive Shapes

There are many benefits to using custom die-cut shapes, including:

Customization

Custom shapes can be customized to fit any application. They can be cut into any shape or size, and can be made from a range of materials to fit specific requirements.

Precision

Die-cutting is a highly precise process, which ensures that the shapes produced are consistent in size and shape. This makes them ideal for applications that require high levels of accuracy.

Time and cost savings

Using custom die-cut shapes can save time and money compared to cutting shapes by hand. The process is highly automated, which means that large volumes of shapes can be produced quickly and efficiently.

Durability

Custom die-cut shapes are made from high-quality materials that are designed to be durable and long-lasting. This makes them ideal for applications that require high levels of durability and resistance to wear and tear.

Applications of Custom Die Cut Self Adhesive Shapes

Custom die-cut self-adhesive shapes can be used in a wide range of industries and applications, including:

Medical

In the medical industry, custom shapes can be used for a range of applications, including wound care, surgical dressings, and medical device manufacturing.

Automotive

In the automotive industry, custom die-cut shapes can be used for applications such as sound insulation, sealing, and gasketing.

Electronics

In the electronics industry, self-adhesive shapes can be used for applications such as shielding, grounding, and insulation.

Packaging

In the packaging industry, custom die-cut self-adhesive shapes can be used for applications such as tamper-evident seals, labels, and product protection.

Construction

In the construction industry, custom die-cut self-adhesive shapes can be used for applications such as sealing, insulation, and soundproofing.

Conclusion

Custom die-cut self-adhesive shapes are highly customizable and versatile products that offer a range of benefits, including precision, time and cost savings, and durability. They can be used in a wide range of industries and applications, from medical to construction, and are an essential component of many products that require protection against contamination and wear and tear.

FAQs

What materials can be used to make custom shapes?

Custom die-cut shapes can be made from a range of materials, including paper, vinyl, and polyester.

What industries use custom die-cut self-adhesive shapes?

Custom die-cut self-adhesive shapes are used in a wide range of industries, including medical, automotive, electronics, packaging, and construction. They are versatile products that can be customized to fit any application and are an essential component of many products that require protection against contamination and wear and tear.

How are custom die-cut shapes produced?

Custom die-cut self-adhesive shapes are produced using a process called die-cutting, which involves using a machine to cut a shape out of a material. The machine uses a sharp blade, or “die,” to cut the material to the desired shape. The process is highly precise, and the shapes produced are consistent in size and shape.

What are the benefits of using custom die-cut shapes?

The benefits of using custom self-adhesive shapes include customization, precision, time and cost savings, and durability. They can be customized to fit any application, are highly precise, can save time and money compared to cutting shapes by hand, and are made from high-quality materials that are designed to be durable and long-lasting.

Can custom shapes be used for medical applications?

Yes, custom self-adhesive shapes are widely used in the medical industry for a range of applications, including wound care, surgical dressings, and medical device manufacturing. They are made from high-quality materials that are designed to be safe and effective for use in medical applications.

In conclusion, custom self-adhesive shapes are versatile and highly customizable products that offer a range of benefits across a wide range of industries and applications. They are made using a highly precise and efficient process and are an essential component of many products that require protection against contamination and wear and tear. Whether used in medical, automotive, electronics, packaging, or construction applications, custom self-adhesive shapes are a reliable and effective solution for masking and protection.

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Rubber Mouldings: What They Are and How They Are Made

Rubber Mouldings

Rubber mouldings are an essential component in many industries, from automotive to construction. These mouldings are used for sealing, cushioning, insulating, and protecting various components, including windows, doors, and electrical systems. They come in different shapes and sizes, and they can be custom-made to fit specific applications.

In this article, we will explore what rubber mouldings are, how they are made, and the different types of rubber used in their production. We will also discuss the benefits and their applications in different industries.

What are Rubber Mouldings?

Components made of rubber that are used to seal, cushion, insulate, and protect different components. They are made by pouring liquid rubber into a mould that has the desired shape and allowing it to cure. Once the rubber has cured, it is removed from the mould, and any excess material is trimmed off.

Rubber mouldings can be made from different types of rubber, including natural rubber, synthetic rubber, and silicone rubber. The type of rubber used depends on the intended application, as each type of rubber has its unique properties.

How are Mouldings Made?

The production of rubber mouldings involves several steps, including mould design, material selection, mixing, moulding, and finishing.

Mould Design: The first step in the production of rubber mouldings is the design of the mould. The mould is designed based on the desired shape and size of the moulding.

Material Selection: The next step is the selection of the appropriate rubber material. The type of rubber used depends on the intended application, as each type of rubber has its unique properties.

Mixing: The rubber material is then mixed with various additives, such as accelerators, curing agents, and fillers, to improve its properties and performance.

Moulding: The mixed rubber material is then poured into the mould, and the mould is closed. The rubber is then allowed to cure, and the mould is opened to remove the finished rubber moulding.

Finishing: The finished rubber moulding is then inspected for quality, and any excess material is trimmed off. The rubber moulding may also be treated with a surface coating to improve its appearance and performance.

Types of Rubber Used in Rubber Mouldings

Rubber mouldings can be made from different types of rubber, depending on the intended application. The most common types of rubber used in rubber mouldings include:

  1. Natural Rubber: Natural rubber is made from the sap of rubber trees and is known for its excellent elasticity and resilience. It is commonly used in applications that require high tear and abrasion resistance, such as in the automotive industry.
  2. Synthetic Rubber: Synthetic rubber is made from petroleum-based chemicals and is known for its excellent chemical and weather resistance. It is commonly used in applications that require high temperature and chemical resistance, such as in the aerospace industry.
  3. Silicone Rubber: Silicone rubber is a synthetic rubber made from silicone and is known for its excellent heat and cold resistance. It is commonly used in applications that require high-temperature resistance, such as in the food and beverage industry.

Benefits

Rubber mouldings offer several benefits, including:

  1. Seal: Rubber mouldings are used to create a tight seal around components, preventing the entry of dirt, moisture, and other contaminants.
  2. Cushion: Rubber mouldings are used to cushion components, preventing damage from impact and vibration.
  3. Insulate: Rubber mouldings are used to insulate components, protecting them from heat, cold, and electrical currents.
  4. Protect: Rubber mouldings are used to protect components from damage, prolonging their lifespan and reducing maintenance costs.

Applications

Rubber mouldings are used in a wide range of industries and applications, including:

  1. Automotive: In the automotive industry to seal doors, windows, and trunks, insulate electrical systems, and cushion components.
  2. Construction: Rubber mouldings are used in the construction industry to seal windows and doors, insulate buildings, and protect components from weather and environmental factors.
  3. Aerospace: Used in the aerospace industry to seal aircraft windows and doors, insulate components, and protect against extreme temperatures and pressures.
  4. Medical: In the medical industry to create seals and gaskets for medical devices and equipment.
  5. Food and Beverage: They’re used in the food and beverage industry to create seals and gaskets for food processing equipment and containers.

Conclusion

Flexible mouldings are an essential component in many industries, providing sealing, cushioning, insulation, and protection to various components. They are made by pouring liquid rubber into a mould that has the desired shape and allowing it to cure. They can be made from different types of rubber, including natural rubber, synthetic rubber, and silicone rubber, depending on the intended application. They offer several benefits, including sealing, cushioning, insulation, and protection, and are used in industries such as automotive, construction, aerospace, medical, and food and beverage. By understanding the different types of rubber mouldings and their applications, you can choose the best for your specific needs.

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Masking during Powder Coating: Tips & Tricks

Masking Tips & Tricks

Powder coating is a popular finishing technique for various metal products due to its durability, appearance, and cost-effectiveness. However, proper masking is essential to ensure that the coating only covers the desired areas and maintains the product’s functionality. In this article, we will discuss several tips and tricks for masking during powder coating to achieve optimal results.

1. Understand the Powder Coating Process

Before masking a metal product, it’s crucial to understand the powder coating process. This includes the type of coating, the curing process, and the temperature required for the process. This knowledge can help determine the appropriate masking materials, techniques, and placement.

2. Choose the Right Masking Materials

The type of masking materials used depends on the product’s size, shape, and complexity. Common masking materials include tapes, plugs, caps, and films. High-temperature masking materials, such as silicone tapes, are suitable for products that undergo high temperatures during the powder coating process. Selecting the right masking materials can help prevent leakage, overspray, and defects.

3. Clean and Prepare the Surface

Proper surface preparation is critical before masking a product. The surface should be thoroughly cleaned to remove any contaminants that could affect the powder coating’s adhesion. The product should also be free from oil, grease, rust, and other impurities. A clean surface helps the masking materials adhere correctly and prevents defects during the coating process.

4. Use Precision Tools

To achieve accurate masking, it’s essential to use precision tools such as cutting knives, scissors, and hole punches. These tools help create precise shapes and sizes of masking materials that conform to the product’s contours. Precision tools also make it easier to remove masking materials after the coating process, minimizing the risk of damage to the product.

5. Consider the Product’s Positioning

The product’s positioning during the coating process can affect the masking requirements. For example, if the product hangs during the coating process, masking materials such as plugs and caps should cover the product’s interior to prevent coating penetration. If the product is flat, tapes and films are suitable for covering the surface areas that require masking.

6. Pay Attention to Overlapping Areas

Overlapping areas can occur when using multiple masking materials, such as tapes and plugs, to cover a product. These areas can create a gap that exposes the product to the coating process, resulting in defects. To prevent this, ensure that the masking materials overlap precisely and create a seamless cover.

7. Test Masking Materials

Testing masking materials before the coating process can help identify any defects or limitations. This includes testing the masking materials’ temperature resistance, adhesion, and flexibility. Testing can also help determine the appropriate thickness and coverage of the masking materials.

8. Remove Masking Materials Carefully

After the coating process, it’s crucial to remove the masking materials carefully to prevent damage to the product. This includes using precision tools to remove the masking materials and avoiding sharp objects that could scratch or damage the product’s surface.

9. Inspect the Product

After removing the masking materials, inspect the product for defects, overspray, or coating thickness. Any defects should be addressed before the product is delivered to the customer. Proper inspection can help ensure that the product meets the required quality standards.

10. Train Employees on Proper Masking Techniques

Proper training of employees on masking techniques is essential to ensure consistent and high-quality results. Training should include the types of masking materials, their appropriate use, and the masking process. Employees should also be aware of the potential risks, such as defects and overspray, and how to prevent them.

In conclusion, masking is a crucial step in achieving optimal results during powder coating. Following the tips and tricks discussed above can help prevent defects, overspray, and ensure that the product meets the required quality standards. Understanding the powder coating process, choosing the right masking materials, cleaning and preparing the surface, using precision tools, considering the product’s positioning, paying attention to overlapping areas, testing masking materials, removing masking materials carefully, inspecting the product, and training employees on proper masking techniques are essential for successful powder coating.

By following these steps, you can ensure that the powder coating process is efficient and effective, resulting in a high-quality finish that meets the product’s requirements. Proper masking can also save time and money by reducing the need for touch-ups and rework.

Masking Tips & Tricks: Frequently Asked Questions:

  1. What is powder coating, and how does it differ from traditional painting?
    • Powder coating is a finishing technique that uses a dry powder applied electrostatically and then cured under heat to create a durable and uniform finish. Unlike traditional painting, powder coating does not require solvents, which can release volatile organic compounds (VOCs) into the atmosphere.
  1. Can any metal product be powder coated?
    • Yes, most metal products can be powder coated, including aluminum, steel, brass, and copper.
  1. What are some common masking materials used during powder coating?
    • Common masking materials include tapes, plugs, caps, and films. High-temperature masking materials, such as silicone tapes, are suitable for products that undergo high temperatures during the powder coating process.
  1. What tips are there for how can I prevent defects during the powder coating process?
    • Proper masking, cleaning and preparing the surface, using precision tools, and inspecting the product after coating can help prevent defects during the powder coating process.
  1. Why is employee training essential for proper masking during powder coating?
    • Employee training is essential to ensure consistent and high-quality results. Employees should be aware of the potential risks, such as defects and overspray, and how to prevent them. Training should include the types of masking materials, their appropriate use, and the masking process.
  1. Can I reuse masking materials?
    • Reusing masking materials is not recommended, as they can lose their adhesive properties or become damaged during the coating process. Using new masking materials for each coating process ensures optimal results and prevents defects.
  1. How do I know if the product is ready for powder coating?
    • Before masking and coating the product, it’s essential to ensure that the surface is clean, free from oil, grease, rust, and other impurities. Testing the surface with a water break test or a solvent wipe can help determine if the surface is ready for powder coating.
  1. What should I do if I encounter a defect after coating?
    • If you encounter a defect after coating, you should inspect the product and determine the cause of the defect. This may involve removing the coating, addressing the defect, and recoating the product. Preventative measures, such as proper masking and surface preparation, can also help prevent defects.
  1. How long does powder coating last?
    • Powder coating can last for many years, depending on the product’s environment and usage. Proper maintenance and care can extend the life of the coating, such as avoiding abrasive cleaning methods and harsh chemicals.
  1. Can I apply multiple colors or finishes during powder coating?
    • Yes, multiple colors or finishes can be applied during powder coating by using different masking materials for each color or finish. This allows for precise application and creates a unique and customized product.

Summing up masking tips & tricks.

Overall, proper masking during powder coating is critical to achieving a high-quality and durable finish. By following the tips and tricks discussed in this article and training employees on proper masking techniques, you can ensure consistent and successful powder coating results. Remember to choose the right masking materials, clean and prepare the surface, use precision tools, consider the product’s positioning, test masking materials, remove masking materials carefully, inspect the product, and train employees on proper masking techniques.

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Masking Products For Metal Finishing: A Comprehensive Guide

Masking for metal finishing

Metal finishing processes like powder coating, electroplating, and anodising are crucial in enhancing the aesthetics and durability of metallic surfaces. During these processes, masking products for metal finishing are used to protect specific areas of the metal that are not intended to be coated, plated or anodised. This is essential in achieving the desired finish and preventing damage or unwanted coating on certain parts of the metal.

This article will provide a comprehensive guide on masking products for metal finishing including powder coating, electroplating, and anodising. We will discuss the various types of masking products available, their applications, and their advantages and disadvantages.

Types of Masking Products Used During Metal Finishing:

Masking products are available in various forms, depending on the nature of the metal finishing process. Here are some of the common types of masking products used during metal finishing:

  1. Masking Tapes: These are adhesive tapes that can be easily applied and removed from surfaces. They are available in different widths and lengths and can be used for masking large or small areas.
  2. High-Temperature Tapes: These are special masking tapes designed for use during high-temperature metal finishing processes like powder coating. They can withstand temperatures of up to 300°C and are ideal for masking areas that require high-temperature resistance.
  3. Masking Caps: These are caps that are used to cover specific areas of a metal surface, like threaded holes or studs, that need to be protected from coating or plating.
  4. Silicone Plugs: These are flexible silicone plugs that are used to mask off holes and other irregular shapes on a metal surface. They are ideal for use during anodising and other chemical finishing processes.
  5. Powder Coating Masks: These are specifically designed masks that can be used for powder coating. They are made from materials that can withstand high temperatures and can be customised to fit specific shapes.

Masking Products Used During Powder Coating:

Powder coating is a popular metal finishing process that involves spraying a dry powder onto a metal surface and then baking it to form a durable and protective coating. Here are some of the masking products used during powder coating:

High-Temperature Tapes: These tapes can be used to mask areas that need to be protected from coating. They are ideal for use during high-temperature powder coating processes.

Powder Coating Masks: These are specially designed masks that can be used to cover specific areas of a metal surface that do not require coating. They can be customised to fit specific shapes and are made from materials that can withstand high temperatures.

Silicone Plugs: These are ideal for masking threaded holes, studs, and other irregular shapes on a metal surface that need to be protected from coating.

Masking Products Used During Electroplating

Electroplating is a metal finishing process that involves the deposition of a thin layer of metal onto a substrate using an electric current. The process enhances the durability and appearance of the metal surface, but it also requires precision masking to ensure that only the intended areas are electroplated. In this section, we will discuss the different types of masking products used during electroplating.

Electroplating Tapes:

Electroplating tapes are specially designed masking tapes that can withstand the harsh chemicals and high temperatures involved in electroplating. They are resistant to the acidic and caustic solutions used during the process, ensuring that they do not dissolve or break down during electroplating.

These tapes are available in different widths and lengths, making them ideal for masking large or small areas. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

High-Temperature Tapes:

High-temperature tapes are masking tapes that are specially designed for use in high-temperature environments. They can withstand temperatures of up to 260°C, making them ideal for use during electroplating, which involves heating the metal substrate to a high temperature.

These tapes are available in different sizes and shapes and are ideal for masking off areas that do not require electroplating. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

Masking Caps and Plugs:

Masking caps and plugs are used to cover specific areas of a metal surface, such as threaded holes or studs, that need to be protected from electroplating. They are available in different sizes and shapes, making them ideal for masking off irregular shapes.

Masking caps and plugs are made from materials that can withstand the chemicals and high temperatures involved in electroplating. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

Conductive Masks:

Conductive masks are used to mask specific areas of the metal surface that require a different electroplating process than the rest of the surface. They are made from a conductive material, usually graphite, and are applied to the surface using an adhesive.

Conductive masks allow for precise masking of complex shapes and are ideal for use in electroplating processes that require different types of electroplating in different areas of the metal surface.

Masking products used during anodising

Anodizing is an electrochemical process that is used to create a protective oxide layer on the surface of a metal. The process involves immersing the metal in an electrolytic solution and passing an electric current through it to stimulate the growth of the oxide layer. Anodizing can enhance the durability and appearance of the metal surface, but it also requires precise masking to ensure that only the intended areas are anodized. In this section, we will discuss the different types of masking products used during anodizing.

  1. Anodizing Tapes:

Anodizing tapes are specially designed masking tapes that can withstand the harsh chemicals and high temperatures involved in anodizing. They are resistant to the acidic and caustic solutions used during the process, ensuring that they do not dissolve or break down during anodizing.

These tapes are available in different widths and lengths, making them ideal for masking large or small areas. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

  1. High-Temperature Tapes:

High-temperature tapes are masking tapes that are specially designed for use in high-temperature environments. They can withstand temperatures of up to 260°C, making them ideal for use during anodizing, which involves heating the metal substrate to a high temperature.

These tapes are available in different sizes and shapes and are ideal for masking off areas that do not require anodizing. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

  1. Masking Dots:

Masking dots are small, adhesive-backed dots that are used to mask specific areas of a metal surface that require protection during anodizing. They are available in different sizes and shapes, making them ideal for masking off irregular shapes.

Masking dots are made from materials that can withstand the chemicals and high temperatures involved in anodizing. They are easy to apply and remove and do not leave any residue or damage to the surface of the metal.

  1. Liquid Masking:

Liquid masking is a masking technique that involves applying a liquid masking material to the metal surface using a brush, spray, or roller. The liquid masking material is typically a latex-based compound that dries to form a protective film.

Liquid masking is ideal for masking irregular shapes and can be used in conjunction with other masking techniques such as anodizing tapes and masking dots. The liquid masking material is easy to apply and remove and does not leave any residue or damage to the surface of the metal.

Advantages & disadvantages of masking products

Masking products are essential tools in metal finishing processes such as powder coating, electroplating, and anodizing. They are used to protect specific areas of a metal surface from being treated, ensuring that only the desired areas are affected. In this section, we will discuss the advantages and disadvantages of masking products.

Advantages:

  1. Precision: Masking products are designed to create precise and accurate boundaries between treated and untreated areas. This level of precision ensures that the intended areas are protected from damage and that the desired outcome of the metal finishing process is achieved.
  2. Versatility: Masking products are available in various types, including tapes, dots, and liquid masks. This versatility allows for the masking of a wide range of shapes and sizes, making them suitable for use in complex and intricate metal finishing projects.
  3. Time-saving: Masking products are easy to apply and remove, making them a time-saving tool for metal finishing processes. They allow for efficient masking of large or small areas, reducing the amount of time spent on the masking process.
  4. Cost-effective: The use of masking products is a cost-effective solution for metal finishing processes. By using masking products, the need for additional treatments or rework is reduced, resulting in cost savings.

Disadvantages:

  1. Residue: Some masking products may leave a residue on the surface of the metal after the masking process, which can affect the appearance of the finished product.
  2. Adhesion: The adhesion of masking products can vary depending on the type and quality of the product used. Poor adhesion can result in the product peeling or coming off during the metal finishing process.
  3. Compatibility: Some masking products may not be compatible with specific metal finishing processes, such as high-temperature processes or processes that require the use of harsh chemicals.
  4. Labor-intensive: The application and removal of masking products can be a labor-intensive process, especially in complex and intricate metal finishing projects.

FaQs about masking products used during metal finishing

In this section, we will answer some frequently asked questions about masking products used during metal finishing.

Q: What are masking products used for in metal finishing processes? A: Masking products are used to protect specific areas of a metal surface from being treated during metal finishing processes such as powder coating, electroplating, and anodizing. They ensure that only the intended areas are affected, resulting in precise and accurate finishes.

Q: What are the different types of masking products? A: There are various types of masking products, including tapes, dots, and liquid masks. Each type has specific properties and applications, making them suitable for use in different metal finishing projects.

Q: How do you select the appropriate masking product for a metal finishing project? A: The selection of the appropriate masking product depends on several factors, including the type of metal being finished, the metal finishing process being used, the size and shape of the areas to be masked, and the level of precision required. It is essential to consult with a professional or supplier to select the appropriate masking product for the project.

Q: Can masking products be reused? A: The reuse of masking products depends on the type and quality of the product used. Some products, such as tapes and dots, are designed for single-use only, while others, such as liquid masks, can be reused.

Q: What are some tips for applying masking products? A: When applying masking products, it is essential to ensure that the surface is clean and free of debris, the masking product is applied evenly, and any air pockets or bubbles are eliminated. It is also crucial to follow the manufacturer’s instructions and use appropriate safety equipment, such as gloves and goggles.

Q: Are masking products environmentally friendly? A: The environmental impact of masking products depends on the type and quality of the product used. Some masking products are biodegradable, while others are not. It is essential to select masking products that are environmentally friendly and dispose of them appropriately.

Conclusion:

Masking products play a vital role in metal finishing processes, providing precise and accurate masking of specific areas of a metal surface. The selection of the appropriate masking product depends on several factors, including the type of metal being finished, the metal finishing process being used, and the level of precision required. It is crucial to follow manufacturer’s instructions and use appropriate safety equipment when applying masking products. The environmental impact of masking products should also be considered, and environmentally friendly products should be selected and disposed of appropriately.

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Manufacture silicone rubber parts | 10 Step Production Schedule

Manufacture Silicone Rubber Parts

Manufacture silicone rubber parts

Custom Parts (Moulded) Production Schedule

Producing custom made silicone parts is something we’ve been doing for decades. We manufacture silicone rubber parts both in the UK and overseas. It’s not just silicone rubber parts we have moulded either.

All our customers have very specific needs and to maintain our zero-returns record, AFAC operates a stringent set of rules to manufacture silicone rubber parts. As you’d expect there’s a formal process we run through to ensure quality of service and solution.

From initial enquiry through to managing ongoing volume needs, AFAC will satisfy, and attempt to exceed, your expectations.

1. Parts defined

  1. It’s perfectly normal for us to expect to sign NDAs at this point.
  2. Whether you wish to manufacture silicone rubber parts that are a modification of an existing design or require a design creating from scratch, AFAC will assist you in proposing a solution to suit your requirement.
  3. To manufacture silicone rubber parts it is useful at this stage to provide .STEP files of the application required to AFAC’s design team for analysis.
    Est. 3-4 days.

2. Drawing created

  1. Our design team will create the necessary files for production to manufacture silicone rubber parts.
    Est. 48 hrs

3. Drawing approved

  1. You will be provided with PDFs clarifying design and dimensions.
  2. It’s important to check all details at this stage to ensure design meets requirements.
    Est. 48 hrs – Customer dependent

4. Drawing sent to production

  1. Acknowledgement of drawing receipt from production.
    24 hrs

5. Prototype tool created

  1. Initially a single impression prototype tool is machined from steel.
  2. Once tool is machined, prototype parts are produced to enable customer approval.
    5 days

6. Prototype parts received

  1. With production being on the other side of the world, you’ll have to wait for a plane to arrive before you receive your prototype parts.
  2. AFAC inspection takes place before forwarding the parts to you.
    5-7 days

7. Prototype parts approved

  1. You’ve now got your prototypes in your hand.
  2. These are fully testable prototype parts. You can take your time to ensure the product is fit for purpose.
    Est. 7-14 days – Customer dependent

8. Production tool created

  1. Ok, the prototypes worked, so now we need your approval.
  2. You’ll have signed the drawing off and paid for your goods in full at this point.
  3. Your multi – impression production tool is then machined from steel.
    21 days

9. Production parts manufactured

  1. Tool made, parts coming out of the mould in volume.
  2. You will have specified colour and shore value earlier in the process.
    21-28 days

10. Shipping

  1. You have a choice here but with choice comes price. It all comes down to how urgent your parts are.
  2. For volume customers we normally recommend only using air to satisfy the 8-10 week requirements until sea shipment arrival.
    Air – 5-7 days
    Sea – 8-10 weeks

Supporting quality manufacturing and metal finishing companies requiring price conscious precision masking supplies. Leading companies from the Automotive, Aerospace, Switchgear & Lighting sectors choose AFAC for reliability, service and price.

Founded over 35 years ago, AFAC has designed, adapted and developed substantial ranges of standard parts supported by a comprehensive bespoke bureau. Engineering backgrounds and family roots give AFAC that competitive edge on service.

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Specialist bespoke metal fabrication requires specialist bespoke silicone rubber mouldings

Bespoke rubber mouldings for masking and other applications in low volume  fabrications.

There are thousands of companies producing low volume metal fabrications for specialist applications in vehicles. This isn’t just specific to motor vehicles either. The UK is not only a leading exported of motor vehicles but also aerospace, defence, shipping and other modes of transport. Trains are also produced in the UK.

The UK has always been famous for pioneering design and bespoke solutions. Whether its military conversions on vehicles, emergency vehicles or any other short production run such as motorsport, the UK is world renowned for design and bespoke manufacturing.

For manufacturers and sub contractors, the processes on short production runs can be very similar to large volume production. The main difference being that the big robotic production lines aren’t often used in low volume manufacturing, but that in its self is why the UK is so different. There are thousands of small engineering firms across the UK producing bespoke assemblies for defence, aerospace, motorsport and specialist vehicles.

By the very nature of bespoke and limited run, masking can also take on a need for bespoke applications. AFAC has over the years produced a wide variety of custom silicone rubber mouldings for these niche industries.

Case study of bespoke silicone rubber mouldings for low volume metal fabrication work

For one customer, when the military were still using Land Rovers as a principle vehicle, they were installing a radio rack into the rear of the vehicle. It was a simple design of a plate with oval holes reamed out of it to allow adjustment of the radio.

The problem was that the bolts and washers used to fix the radio to the plate were also the earthing points. As a result, an area around each oval hole needed masking to allow for the movement that had been built into the design.

Using the BAKEWELL Silicone Rubber TUGPLUG as a basis for the design, we created an oval section and then added a “washer” into the design with a sealing lip around the edge for quality of finish. The first design was prototyped and worked perfectly.

Tooling is relatively inexpensive and the production run was only a matter of a few hundred items.

The Outcome

Satisfied customer and problem solved.

Working on limited volume fabrications and have a need for custom rubber mouldings or extrusions? Get in touch right now on 0845 094 0522

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Protecting and masking delicate precision metalwork during media blasting

How to protect and mask delicate precision metalwork during media blasting processes in aerospace applications

One aspect of the work we do at AFAC is to be problem solvers on behalf of our clients. Of course, more often than not a client knows exactly which product they need and our role is simply to fulfill the order. But occasionally a customer will come to us and explain a particular problem they have—and in these cases it’s down to us to configure a solution.

We recently had a situation like this that certainly required some ingenuity on our part to solve.

Our client in this case was a well-known manufacturer of aircraft engines, low-emission power systems for ships, road and rail vehicles and electrical generators. The company approached AFAC because they were facing a particular problem in the maintenance of their aircraft engines. They had discovered that when some of the engines would come in for maintenance, there would be paint peeling off them in certain areas. Given that these are still new engines that would be going out to very prestigious clients, the company decided that they needed to address the problem.

One task of the maintenance team is to strip the coatings from the affected parts and then recoat them. They use a media blast to strip away the original coating, but they were finding the powder they were using for the media blasting was distorting the metalwork. This was making it impossible to satisfactorily refit the pieces to the engines.

The company came to us and explained the issue. We came up with a solid mask to reinforce the metalwork from behind while it was being blasted. As a result the integrity of the shape was maintained and the metalwork remained in a condition suitable for recoating and refitting to the engines, representing a significant money saving for the manufacturer.

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Creating bespoke silicone rubber moulding for manufacturing case study

Bespoke Silicone Rubber Moulding

Case Study: Creating a bespoke silicone rubber moulding to speed up manufacturing

Sometimes, when a client comes to us with a unique problem that needs solving, we create a bespoke silicone rubber moulding for them. Then, having created a solution to the problem, we realise that there may be other customers facing the same problem. The result? A new product line available to all our clients.

This scenario is precisely what happened when we were approached by an international client who had a finishing problem. The company in question is a leader in secondary power distribution solutions with an outstanding pedigree. The business specialises in high-performance medium voltage switchgear for industrial, utility and commercial applications. Incredibly, they have more than 100 years’ experience in enabling the safe and reliable distribution of energy all over the world.

The problem they consulted us about was this: they were looking for a cap that would protect the threaded ends of studs during media blasting to remove oxides and scale from their steel assembly. The cap would also need to act as a mask during electro-static powder coating. However, the caps they were using couldn’t withstand the punishment of shot blasting.

It was time for the AFAC team to step in. We designed a beefed-up version of the T-Cap. It has heavier walls and it doesn’t have the lip feature that the standard caps have. The reason for omitting this is that the blasting process is so fierce it tends to blast the cap completely off the stud. The resulting design for the new cap has increased wall thickness, no lip and a modified top flange to withstand the strain of being pulled off. As an extra precaution, the bore of the cap has also been reduced to give an increased friction fit—a further measure to help it remain in place during blasting.

The result was a winner! The new cap is able to withstand the rigours of blasting and the customer has requested a range of similar caps to use with different sizes and lengths of studs. These robust caps are now also available to our other customers. So one client’s problem resulted in all our clients gaining a new product!

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Manufacturing using 3D Printing – Roll on the Revolution!

How will manufacturers benefit from 3d printing?

Most of us have known about the advent of 3D printing for a while now. But what the inventors haven’t so far been able to show us is how its application is going to revolutionise certain industrial manufacturing processes. However, forward thinking businesses, such as AFAC, are starting to explore its potential—and now that it’s possible to 3D print in rubber, we can see a great future ahead!

3D printing – what is it and how does it work?

If you’ve seen a 3D printer at work, it’s an extraordinary sight to behold. A template in the form of a computer generated .cad file gives the printer its template. Press ‘PRINT’, and a stream of plasticising powder is fused with a bonding element to form a 3D plastic reproduction of the template. Furthermore, the technology has the ability to recreate complex objects, complete with moving parts—and all to an incredible degree of accuracy. But it’s not just plastic creations that can issue forth from the latest 3D printers. New printers have been unveiled that can create complicated multi-coloured sweets from sugar and chocolate. Just what the world has been waiting for!

To see an amazing 3D print out, take a look at this QI clip.

New 3D printing applications in manufacturing

However, more useful applications might not have the novelty value of spun sugar but they may revolutionise manufacturing as we know it. For AFAC, the eureka moment came when Ryan Mullins discovered that 3D printing in rubber is also available.

Rubber? What’s the big deal?

To date, most 3D printing has used plastic. For AFAC, plastic prototypes are not ideal for demonstrating a wide range of products which are generally made from rubber. The rigid nature of plastic doesn’t adequately show how the rubber and silicone plugs and covers will perform.

However, using a 3D printer to create rubber prototypes represents a game-changer for two reasons:

  • For AFAC, the properties of rubber are an integral aspect to the product design and effectiveness of proving concept for the vast majority of its products. In future, we will be able to utilise 3D rubber printing to produce rubber items with varying shore values as a way to provide the fastest and most efficient prototyping service for our clients. Lead times in bespoke product development will be slashed.
  • As 3D printing technology advances, costs will fall and its use will become widespread in all areas of mass production. 3D printing in rubber will reduce the cost of custom mouldings production. Tooling costs will exchanged for cheaper printer set-up charges and bespoke rubber prototypes will become available overnight. We’re not there yet, but with advances in the technology to increase the variety of materials and colours available, we will be soon.

3D Printing for designers and product development

For product designers and developers, this represents a massive leap forward. It’s conceivable that one could move from idea to full production in just a matter of hours. And with your own in-house 3D printing facilities, fears about product protection and pirating simply evaporate.

The UK has built its reputation on the extraordinary skill of its niche designers and product developers. 3D printing will hopefully allow more of the subsequent manufacturing to be based once again on British soil. And hopefully, AFAC will be one of the companies leading the way.