Secondary process

Product surface plating, product laser engraving、 spraying、 product ultrasonic assembly, product hot melt assembly...

Secondary Processes

Secondary, Post-Processing, or Finishing Options can all be used to enhance and protect injection-molded plastic parts. Post processing can add functionality or simply provide a uniform appearance. There are a variety of secondary operations that customers can choose from to customize their product. The experts at Formexmold by Fathom have decades of combined experience in the injection-molding field and can lead customers through the process from design, to molding, to finishing operations. Injection molding secondary processes include painting, welding, post-mold machining, assembly, and packaging.

What are the Post Processing Steps in Injection Molding?

That depends entirely on the intended end use of the product and the type of secondary processing required. Post processing options can be anything from painting to assembly. Formexmold offers a full suite of injection molding secondary services to guarantee your product will be ready for use when it arrives from our manufacturing facilities.

Ultrasonic surface processing

Ultrasonic surface processing utilises the cold plasticity characteristics of metals at room temperature, employing ultrasound to carry out grinding, strengthening and minor deformation treatment on metal parts surfaces without the use of abrasives, enabling the surface of metal parts to achieve a more ideal surface roughness. It can also be vividly described as using ultrasound to smooth the surface of parts; at the same time, it generates compressive stress on the surface, improving the microhardness, wear resistance and corrosion resistance of the part surface, thereby extending fatigue life.

Ultrasonic surface machining

Purpose Increase hardness, wear resistance and corrosion resistance, and prolong lifespan

Principle

Increase hardness, wear resistance and corrosion resistance, and prolong lifespan

Hot melting processing

Hot melt

Hot melt is a type of welding technology for thermoplastic materials, belonging to the category of hot melt welding. It refers to the process of pressure connection by heating the end face of the material to a molten state. It is mainly used in the processing of plastic pipes such as polyethylene (PE) and polypropylene (PP), covering the fields of gas, water supply, chemical and aviation composite materials [1-3]. According to the joint form, it can be divided into three types: hot melt butt welding, hot melt socket welding, and hot melt saddle welding. A special welding machine is required, and the welding parameters include temperature (200-235 ℃), pressure (0.07-0.45MPa), and time (such as heat absorption time=wall thickness x 10 seconds).

Category:

Hot melt welding
Introduction:

Two PE pipes are melted and connected as a whole Field processing

Secondary Processes

Injection Molding Post Processing at Your Fingertips

Formexmold offers a convenient online project quoting system. Our injection molding calculator system can return a quote for your project in seconds. Simply create an account and upload a CAD file. The project calculator will return a quote almost instantly. An Formexmold engineer will then examine the CAD file. The engineer will confirm the quote and project viability. From there the project can move in to production.Part of the online quoting system includes an option to select secondary processes. These processes include painting, ultrasonic welding, hot plate welding, heat pressing, heat staking, post-molding machining, pad printing, and screen printing.Formexmold also offers additional, value-added services to help get your parts finished, assembled, and even packaged. Parts will arrive packaged and ready to ship out to stores and customers.

Molds are indispensable and crucial tools in industrial production, widely used in fields such as household appliances, automobiles, electronic devices, and medical equipment. The texture and patterns on mold surfaces play a vital role in product quality and appearance. With the rise in consumer spending levels, traditional mold engraving methods have certain limitations and fail to meet the demands for fine texture and complexity in high-end products. The emergence of laser engraving technology for molds has introduced entirely new possibilities for mold surface treatment.

Principle of Laser Etching Technology for Molds

3.1 Laser emission
The laser produces a high-intensity, high-energy laser beam. These laser beams are typically generated by laser diodes, solid-state lasers, or gas lasers.
3.2 Laser Focusing
The laser beam passes through an optical system, such as a lens or mirror, and is focused into a very small laser spot. The focused energy density determines the depth and accuracy of the etching pattern.
3.3 Surface irradiation of molds
The focused laser beam is irradiated onto a specific position on the surface of the mold. The interaction between the laser beam and the mold surface causes the melting, evaporation, or peeling of the material, resulting in the formation of the desired patterns and textures.
3.4 Movement and Control
Molds are usually combined with CNC machine tools or laser etching machines to achieve etching of the mold surface by controlling the relative motion between the laser beam and the mold. These movements can be the rotation, translation, or tilting of the mold.
3.5 Coordination and Control
Through advanced computer control systems, the laser source, optical system, and mold motion are coordinated and controlled. This enables the laser etching process to be carried out with very high precision and repeatability.
Mold laser etching technology utilizes the high energy and precise control of the laser beam to achieve high-precision etching of the mold surface, thereby forming fine patterns and textures. This non-contact processing method has the advantages of high efficiency, high precision, and repeatability, and has gradually become an important technology in the field of mold processing [4].

Application of Laser Etching Technology in Molds

4.1 Automotive Industry
Car mold is one of the important application areas of laser etching technology for molds, which is used for surface texture treatment of automotive interior parts, steering wheel, dashboard, door panels, seats and other components. By laser etching, various fine textures can be created, which can enhance the texture and aesthetics of car interior decoration, improve the appearance quality and comfort of the car. The laser etching effect on the mold is shown in Figure 2 [5].
4.2 Electronic Products
In high-end electronic products, mold laser etching technology is commonly used for pattern and texture processing on the shells of mobile phones, displays, projectors, tablets, and laptops. These patterns and textures not only enhance the visual appeal of the product, but also provide better hand feel and anti slip performance. The appearance texture of electronic products greatly enhances the user experience. Laser etching technology for molds can form delicate and uniform textures on electronic product casings, buttons, and displays, enhancing the appearance, texture, and quality of the product, and effectively enhancing its competitiveness among users’ numerous choices.
4.3 Medical Devices
The surface texture of medical devices has a significant impact on the hygiene and operability of products. Through mold laser etching technology, fine textures can be formed on the surface of medical device components during the manufacturing process, making it more comfortable for medical personnel to operate the medical device and easier to clean. At the same time, the delicate laser etching can effectively improve the antibacterial properties of the product.
4.4 Furniture and Supplies
The application of mold laser etching technology in household products is also receiving increasing attention. For example, texture treatment can be applied to the surfaces of furniture, lighting fixtures, and kitchen supplies to give them higher texture and artistic value. The laser etching effect on jewelry is shown in Figure 3.

Injection Molding Post Processing Options

Painting: Painting is one of the cheapest ways to enhance the look of your product. There are various painting methods available including spray painting and powder coating. The type of painting process utilized will be determined by the chemical characteristics of the plastic and its eventual end use.
Ultrasonic Welding:Formexmold’s ultrasonic welding process uses high frequency mechanical sound waves to create molecular heat between thermoplastic materials. This will cause the plastic to melt and form a molecular bond between the parts.
Hot Plate Welding:The hot plate welder uses a heated platen to melt the joining surfaces of the two halves of a thermoplastic part. Hot plate welding allows precise control of the melt temperature, excellent weld strength, and the ability to weld large, complex parts. View this hot plate welding video to learn more.
Heat Pressing: Metal inserts are placed into the plastic parts. This secondary process is done by using heat and pushing the inserts into the parts.
Heat Staking: This process joins two parts by inserting the stud of one part into a hole in the other part. The stud is then deformed with heat to mechanically lock the parts together.
Post-Molding Machining: Additional Computer Numerical Control (CNC) machining can be done after the plastic injection molding process is completed. This machining can be used to remove flash (excess plastic), change the shape or texture of the part, or prepare the part for further post processing.
Pad Printing & Screen Printing:
Pad and screen printing are used to place colored graphics on parts. This can be done for branding, labeling, or part number identification. Screen printing is ideal for adding graphics that require multiple colors. However, there are some limitations to the screen-printing process. Screen printing requires a relatively flat surface for printing. Pad printing is a versatile finishing option. Pad printing can be used almost anywhere on the part.
Assembly: Formexmold by Fathom can assemble the parts if needed. Simply supply all needed materials and Formexmold will take care of the rest. Parts will arrive fully assembled and ready for use.
Packaging: Formexmold can produce, assemble, and package your product. After production and assembly, the parts can be packaged into clamshell/blister packs, boxes, insert header cards, etc. The product will be packaged and ready to sell or ship out upon delivery.Contact the experts at Formexmold by Fathom to learn more about injection molding post-processing options. Or visit our quoting page to request a quote for a custom plastic injection-molding project with secondary processes.