custom vacuum casting

How does the prototype manufacturer process the surface?

  1. Manual grinding and polishing

This method does not require special equipment, and its adaptability is relatively strong, mainly depends on the experience and technical level of the worker, and the efficiency is low (about 1/3 of the entire prototype model cycle).

  1. Digital prototype polishing machine

This polishing tool adopts digital control, digital display and control of process parameters, and is equipped with a complete set of grinding heads and abrasives for semi-automatic polishing. It has the advantages of small size, convenient use, stable quality and good repeatability. Application scope: a. Material: various prototype materials, including cast steel, forged steel, aluminum alloy and zinc alloy. b. The surface size of the prototype: 100×100 (mm)-1,500×3,000 (mm).

  1. Ultrasonic hand polishing machine

It can complete the polishing of narrow grooves, slits, edges, corners, etc., which are difficult for ordinary polishing tools (electric grinding soft shafts, etc.) to penetrate. The edges and corners will not collapse after polishing, and the accuracy of the prototype model will not be affected. Using this tool for polishing can quickly reshape and polish rough surfaces without being limited by the shape of the workpiece and the hardness of the material, and has no requirement on the original surface roughness, and the efficiency is relatively high.

The E-make team has more than 30 years of combined experience in prototype machining, CNC manufacturing(metal, plastic parts machining), vacuum casting service and 3D printing service. And The E-make company has been providing high quality rapid prototype manufacturing services for major enterprises.

Please feel free to contact us. If there is anything we can do for you!

die casting aluminum parts

CNC Machining And Die Casting Process

CNC Machining And Die Casting Process
For metal made product,we all know they can be made by CNC machining process or die casting process,but there are much difference between them.
CNC machining is a precision machining process,including CNC milling,CNC turning,CNC drilling,etc.The Advantage of CNC machining is as following.
A,CNC machining can process the workpieces with complex shape,which no need to use complicated tooling.Also,If we need to modify the shape or the dimensions of the workpiece,we just need to change the the machining program.That is why CNC machining is more suitable for manufacturing the new product in prototype stage.
B,The quality of the workpiece made by CNC machining is stable, also,the machining accuracy and the repeated machining precision is high.
C,The production efficiency is higher in the case of multiple varieties and small batch production,which is helpful to reduce production preparation, machine adjustment and process inspection time.
D,Most of materials can be made by CNC machining,such as wood,bamboo,plastic (ABS,POM,PC,PMMA,PTFE,bakelite,etc) and metal (aluminum,copper,brass,steel,etc).
E,Most of the surface treatment process can be used for the CNC processed products,such as anodizing,painting,electroplating,powder coating,sandblasting,etc.
The disadvantage of CNC machining is high technical requirements for machine operators and machine maintenance personnel,also the production cost is more expensive and not cost-effetive for the bulk production,on the contrary,die casting process is very cost-effetive for the production of large quantities of metal products.Even Though,die casting also have it’s advantage and disadvantage.
Die casting process is a kind of metal casting,the characteristic is by using the inner cavity of the mold to apply high pressure to the molten metal, which is similar to the process of injection molding.Most of die castings do not contain iron, such as zinc, copper, aluminum, magnesium and other materials are formed by alloy casting.
The advantage of die casting process
A,As we said above,die casting is very cost-efftive way for the bulk prodution of metal parts,expecially the small and medium size metal parts.
B,Comparing with the other casting process,the surface of die casting is more smooth,so the product size consistency is very high.
C,The production efficiency of die casting is very high.
D,After mold finish,it can be used to casting at least tens of thousands of products,so the cost of the unit parts is very low.
The disadvantage of die casting
A,Due to the high filling speed of liquid metal in the mold cavity and unstable flow state,if use the general die casting method,the castins is easy to produce pores and cannot be heat treated
B,Die casting is hard to produce the castings with complex concave;
C,The tooling is very expensive,so die casting is not suitable for small batch production.
D,The material that die castings can use is limited.

Therefore,for developing the new products or small batch production or the product with very complex structure,CNC machining process might be a better option.But for the mature product with great sales and require large quantity,die casting may more suitable.

Customized Acrylic Rapid Prototype Machining Service

Making Acrylic Prototype By 3D Printing,Vacuum Casting Or CNC Machining

Making Acrylic Prototype By 3D Printing,Vacuum Casting Or CNC Machining
For small batch production,if we need to make the plastic product with acrylic material,generally we will prefer to make them by 3D printing process,vacuum casting process or CNC machining process.We can make the acrylic product by all this three process,but there is much difference bewteen them,whatever the machining way or the finished product.
1.The difference of the machining way.
If make by 3d printing,we will obtain a acrylic product but not transparent after printing,and then polish and painting UV coating to make them transparent.
If make by vacuum casting,firstly we need to make a master mold of the product by CNC machining or 3D printing,and then we will polish the master mold to make them have a smooth surface,after that we will use the master mold to make a silicone mould,so that we can have a mold for casting.Finally we will remove the burr of acrylic parts and polish it to be total transparent.
If make by CNC machining,we will need to program firslty,and then milling or turning the acrylic parts by CNC machine,after that,we wtill need to polish the product to make it total clear.
2.The difference of the material.
If make by CNC machining,we can use pure acrylic sheet material or bar material,so the strength of the product that make by CNC machining will be better.
If make by vauum casting,the material we can use is similar acrylic,not pure acrylic,so the product that make by vauum casting is not strong as the product that make by CNC machining.
3.The difference of the processing time.
It will takes more processing time if make the product by CNC machining becase we need to make the product one by one on the CNC machine.
It will be more fast if make by vacuum casting because we can casting 8-10 pieces high quality product by using one mold.
It will be very fast if make by SLA 3D printing.
4.The difference of the product precision.
The product can have very high precision if make by CNC milling,so if the customer require high precision for the product,CNC machining process is a better option.
The precision of the product that make by vacuum casting is not so high as CNC machining,and the precision of the product that make by 3D printing is more low.
5.The difference of the price.
Generally,the cost of the product that make by CNC machining is more expensive,but the final cost depends on the product specification that customer require.

our cases mock up 2

Prototype model can avoid the risk of making molds

Prototype models can avoid the risk of producing molds, reduce the time for products to come out, and have a great help in seizing the market. You can also use the prototype products for publicity planning before the development and design of the model, and even make early market sales. And the production site management work. Prototype models are divided into three categories: appearance prototypes, structural prototypes, and vacuum casting.
Appearance prototypes are mainly used to test product appearance specifications, color matching, material interaction, cost evaluation, and market research; Structural prototypes are key to interactions between the internal installation structure of the product, material compressive strength analysis, characteristic inspection, and Cost evaluation, new product investment,etc.,thereby reducing the risk of immediate production of molds.
Vacuum casting is mainly used to test various characteristics of new products in small batches, further improve the feasibility analysis of mass production of new products, and that can also be used to attract new products.
The E-make team has more than 30 years of combined experience in prototype machining, CNC manufacturing, vacuum casting service and rapid prototyping service. The processing quality of the rapid manufacturing is stable, the processing precision is high, and the appearance is exquisite.
The E-make company has been providing high quality rapid prototype manufacturing services for major enterprises. If you need any help, please feel free to contact us!

sheet metal stamping working

Sheet Metal Fabrication

Sheet Metal Fabrication
Machining metal sheet material also called as metal plate fabrication,which mainly include cutting,bending,brake forming,stamping,welding,riveting and so on.Regarding sheet metal,we probably can understand that is a parts of constant thickness during processing.
Sheet metal is widely used in mechanical manufacturing,for example,we usuallly will use metal plate for making chimney,metal bucket,ventilation shaft,oiler,etc.
About the material,sheemt metal fabrication generally will use such as SPCC,SHCC,SECC,SGCC,copper,brass,red copper,beryllium copper,stainless steel (mirro surface,brush surface,matte,etc),aluminum (6061,6063,hard aluminum,etc).The manufacturer will offer their suggestion according to the use of the product,the cost that customer require.
1.SPCC mainly be used in electroplated parts and coated parts.The thickness of SPCC sheet parts is thinner than 3.2mm,with low cost and easily formed.
2.Like SPCC material,SHCC material mainly be used in electroplated parts and coated parts,with low cost.But the thickness of them are thicker than 3.0mm,also,they are hard to be formed.Mostly will be used for flat components.
3.SECC and SGCC material mostly for the parts that do not require surface treatment.Also,the cost for make them are highly.
4.Copper mostly for the product that require conduction of electricity,which will takes high cost.The surface finish for copper generally is nickel plating,chrome plating or without surface finished.
5.The surface treatment we usually will use for aluminum alloy material is anodizing,silver plating,nickel plating.
6.The section aluminum material with complex structure mostly will be used in subrack.
7.The stainless steel material made parts generally without surface finish.
The ways to cut material in metal plate machining as following.
1.The shears mostly is for cutting the simple shape material,tolerance is lower than 0.2mm,which are with low cost,but only can be used in machining the sheared strip or lump material.
2.The puncher can cutting the material into kinds of shape,the advantage of making sheet metal by puncher is with short time production,high efficiency,high tolerance and low cost,which are suitable for bulk prodcution,but it will need to make mould before producing.
3.About cutting the material by NC,we will need to programm before machining.The feature of this machining way is with low cost and tolerance is 0.15mm,but the structure of parts will be effcted by the structure of the tool.
4.We also can use laser cutting process to cut the material out of shape.Like the way of NC,laser cutting also need to programm before working,This way can cut the flat piece with complex shape,and tolerance is 0.1mm,but the cost of this way is high.
5.The saw machine can be usd in such as section aluminum,square tube, diagram tube and round bar material,also with low cost and low tolerance.

CNC Machining Technology

The Process Of CNC Machining

The Process Of CNC Machining
1.Confirm the machining area and the specification of machined parts.
a)Firstly,determine what process has been used to process this workpiece before and what process will be used to process it, and then confirm the relationship between these processes.
b)The condition of the workpiece before.For example,it was a casting parts or a forgeable piece or a bar parts,and the shape,the dimension,the machining allowance of workpiece and so on.
c)What area and shape need to be machined in next process.
2.Confirm the clamping way of the workpiece and design the fixture.
Select and design the fixture according to machining area,locating basis and clamping requirement of the workpiece.Mostly CNC machine will use three-jaw self-centering chuck to clapm the workpiece.
3.Confirm the machining method.
a)Determining the process principle,generally there are first rough then essence, near then far,inside then outside,the least procedure section, the shortest tooling route and special cases for special treatment.
b)In order to improve the production efficiency and ensure the finish machining quality of parts, the rough machining process shall be arranged first during cutting, and a large amount of machining allowance before finish machining shall be removed in a short time, and the allowance uniformity requirements of finish machining shall be met as far as possible.When the roughing process is finished, the semi-finishing and finishing should be arranged after the tool change.The purpose of arranging semi-finishing is when the uniformity of the remaining allowance after rough processing can not meet the finishing requirements,it can arrange semi-finishing as a transitional process,so that the finishing allowance is small and uniform.
c)Near than far is according to the distance from the machining position to the tool.Generally,to shorten the tooling distance and reduce the idle time,we will machining the position that more closed with the tool when are rough machining.Near than far is good for turning processing,whhich are the cutting conditions can be improved and keeping the rigidity of the blank or semi-finished parts.
d)For the parts need to be machined both of the inside surface and the outside surface ,we should machining the inside before outside when we are planning because it is difficult to control the size and shape of the inner surface, the tool rigidity is correspondingly poor, the durability of the tip edge is reduced by the heat of cutting,and chip removal is difficult during machining.
The above principles are not set in stone,some special cases may require a flexible approach.For example,some workpiece must be finished after rough processing to ensure its processing accuracy and quality.

injection moulding bg pic

Analysis of the five elements that need to be met in injection molding

Plastic molding is the process of making various forms (powders, pellets, solutions and dispersion) of plastics into products or blanks in the desired shape.The manufacturing process of most cosmetic packaging materials is mainly through the four key processes of mold molding, surface treatment,printing,and assembly.The molding process is an indispensable key part.Injection molding is a method of producing shapes for industrial products.Products usually use rubber injection molding and plastic injection molding.Injection molding can also be divided into injection molding compression method and die-casting method.Injection molding machine is the main molding equipment that uses plastic molding molds to make plastic products of various shapes. Injection molding is realized by injection molding machines and molds.

The five elements that need to be met in injection molding are:

  1. Temperature:Temperature is the first step of injection molding.Temperature can be divided into:drying temperature,material temperature,mold temperature, these are some of the most important factors.The drying temperature is to dry the polymer in advance in order to ensure the quality of the molding,to ensure that the dry and wet of the polymer are within a certain amount;The material temperature is to ensure that the polymer is plasticized normally,and the mold is filled and formed smoothly;
  2. Speed:Speed is divided into:injection speed,Melting speed,loosening and retreating speed,opening and closing mold speed,thimble forward and backward speed.The increase of the injection speed will affect the increase of the filling pressure,and the increase of the injection speed can increase the flow length,and the product quality can be uniform to ensure the quality of the product.High-speed injection is suitable for long-process products,and the size of the product is controlled at low speed;Melting speed affects plasticizing ability,plastic mold processing is an important parameter of plasticizing quality,the higher the speed,the higher the melt temperature,the stronger the plasticizing ability;
  3. Pressure:Pressure is divided into: injection pressure,holding pressure, back pressure,clamping pressure,mold protection pressure,ejection pressure.
  4. Position:The position can be divided into:mold opening position, ejection retreat stroke,metering stroke,leg loosening amount,injection stroke,and buffering amount.The mold opening position is to ensure the normal operation of the demolding parts.The effect of the ejection back stroke on the partial spring return to the ejection limit protection.The metering stroke is to ensure that there is enough plastic to fill the mold to ensure product quality.
  5. Time:The time is divided into:cooling time,sol time,drying time, cooling time,melting time,drying time,cycle,injection time,and pressure holding time.The molding of plastic shell paintingproducts requires a certain period of time.The holding time is to prevent the melt back flow and cooling shrinkage.The cooling time ensures that the product is solidified and prevents deformation;the melting time is to ensure that the glue is fully melted;the drying time is to ensure that the product does not become elongated or defective.

The E-make company has 30 years of experience in custom-made production of injection molding.The plastic injection molding products will be exquisite in appearance,reliable in quality and delivered on time.If you want to customize the high-precision injection molding products.All information from customers was kept secret,we can sign NDA with you before starting any work.If you need any help,please feel free to contact us.

sheet metal fabrication

Sheet Metal Working

Sheet Metal Working
With the characteristics of light weight, high strength, conductivity, low cost and good mass production performance,metal plate is a technology that has been widely used in electronic and electrical appliances, communication, automobile industry, medical devices and other fields. For example,it is an essential part in computer chassis, mobile phone,and so on.
The material of metal plate widely be used in electronic enterprises is SPCC,SECC,SGCC,SUS301,SUS304,etc.There are three main types of sheet metal processing: blanking, bending and stretching. Different processing technologies have different requirements for sheet metal. The selection of sheet metal also need be considered according to the shape of the product and processing technology.The following is the impact of materials on sheet metal processing technology.
a,The influence of materials on punching process.
Punching requires that the plate material should have enough plasticity to ensure the plate will not crack during machining.The soft materials such as pure aluminum,antirust aluminum, brass, red copper and mild steel have good punching performance,which can be blanked to the parts that have a smooth section and a small inclination.The quality of the hard materials is not good after punching,such as high-carbon steel,stainless steel,duralumin and ultralumin, the section unevenness is large, especially for the thick plate material.
b,, The influence of materials on bending process.
The plate materials to be bent should have sufficient plasticity and low yield limit.The plate with high plasticity is not easy to crack when bending. The plate with low yield limit and low elastic modulus has small rebound deformation after bending, and it is easy to obtain the bending shape with accurate size. Materials with good plasticity such as low carbon steel, brass and aluminum with carbon content less than 0.2% are easy to bend and form; Materials with high brittleness, such as phosphor bronze (qsn6.5 ~ 2.5), spring steel (65Mn), hard aluminum, superhard aluminum, etc., must have a large relative bending radius (R / T) during bending, otherwise they are easy to crack during bending.
c,The influence of materials on tensile process.
Sheet metal stretching, especially deep stretching, is a difficult kind of sheet metal processing technology. It not only requires the stretching depth to be as small as possible, the shape to be as simple and smooth as possible, but also requires the material to have good plasticity. Otherwise, it is very easy to cause overall distortion, local wrinkling and even tensile cracking of the parts.

rim

Rapid prototyping manufacturing service

The inspection design prototype is not only visible,but also touchable. Therefore,the prototype can vividly reflect the artistic creativity of the interior designer in a physical way,preventing “drawing beautifully but making it unsightly”Shortcomings.So,prototype manufacturing is indispensable in the development of new products and the deliberation of product appearance.

Check the structural design.Since the prototype is installable,the prototype can visually reflect the effectiveness of the product structure and the level of difficulty of installation,which is conducive to finding problems and solving difficulties in time.

Prevent the risk of opening the mold immediately,because the cost of mold processing is generally very high.If the structure is found to be unscientific or other problems in the process of mold opening,the damage is obvious.Prototype manufacturing can prevent such damage and reduce the risk of mold release.

Make the product launch time much earlier,because of the advancement of prototype production,you can use the prototype for product promotion before the mold is developed,and even the early sales and production preparations to occupy the market as soon as possible.

According to the manufacturing process,the prototype is divided into CNC prototype and manual prototype;

CNC prototypes are mainly produced and processed by CNC machines. According to different production equipment,they are divided into laser rapid prototyping technology and CNC prototypes.

During this period,the prototypes of laser rapid prototyping technology are mainly matched with SLA prototypes,that is,prototypes produced and processed by using the skills of laser rapid prototyping technology. In fact,it matches with other CNC prototypes:CNC prototypes.That is,the CNC machine is used to produce the processed prototype model.

Advantages of CNC prototype:The advantage of the CNC prototype is that it can accurately reflect the information content represented by the engineering drawings.The surface quality of the CNC prototype is very high, especially in the middle and later stages of production and processing.The parts need to be painted.Therefore,CNC prototype manufacturing has increasingly become the mainstream of the prototype manufacturing industry.

If you want the prototype model to be close to the finished product and to detect the actual effect of the appearance,you must make a prototype model.After the prototype model is completed,it must be polished. What is the polishing of the prototype model?

Prototype model polishing is to eliminate burrs,oily dust on the surface of the part or the surface of the material,reduce the surface roughness of the surface of the product,and improve the adhesion of the coating after polishing the old paint film.Prototype model polishing can be divided into traditional manual polishing and modern polishing.

After a prototype part is CNC processed,its surface will inevitably cause many burrs and knife marks.At this time,it is necessary to manually solve this problem manually.Generally,people will choose sandpaper for sanding,or sanding and polishing.The basic appearance solutions include sanding,sandblasting,sanding and polishing,coloring,silk screen ink,and electroplating.

As a professional manufacturer,we have the capabilities to produce the finest Visual Design Models,Full-functional Engineering Prototypes or Low volume production runs that allow you to proof your designs thoroughly,and help you to focus on key elements of product development.

If you need any help,please feel free to contact us!

CNC MILLING MACHINING

CNC Milling Machining Technology

CNC Milling Machining Technology
The process of CNC machining have much impact on the quality of the product that produced by CNC machining,and the CNC machine play an important role in the CNC machining ptocess.
Comparing with the normal machine,the CNC machine have some characteristics as below:
A,It has strong adaptability to the processing object, adapt to the characteristics of mold and other single-piece production,and provides a suitable processing method for mold manufacturing;
B,It can be used in prototype production or small batch production.
C,The parts made by CNC milling have high precision and stable processing quality.Generally,for metal parts,the precision can meet 0.01-0.1mm.When processing the same batch of parts on the same machine tool and under the same processing conditions, using the same tool and processing program, the tool path is exactly the same, so the consistency of parts is good and the quality is stable.
D,The tool of CNC machine can move in multiple coordinates and process parts with complex shapes.
E,If customer need to change the shape or structure of the machined parts, generally we only need to change the program,which can save production preparation time;
F,The CNC machine has high precision and high rigidity, so that we can choose our favorable processing material dosage,which are more productivity.
G,It is conducive to the modernization of production management. CNC machine tools use digital information and standard code to process and transmit information, and use computer control methods, which lays a foundation for the integration of computer-aided design, manufacturing and management
H,Processing parts on a CNC machine tool mainly depends on the processing program. It is different from an ordinary machine tool. It does not need to be manufactured, many molds and fixtures are replaced, and the machine tool does not need to be re-adjusted frequently. Therefore, the CNC machine tool is suitable for the occasions where the processed parts are frequently replaced, that is, it is suitable for the production of single-piece, small-batch products and the development of new products, thereby shortening the production preparation cycle and saving a lot of process equipment costs.
I,CNC machine require more higher quality requirements for operators and higher technical requirements for maintenance personnel;
E-make are professional in CNC milling machining years,if you have project need to make with metal,plastic,wood or Macro by CNC milling,please don’t hestate to contact us.