Post Processing
Manufacturing Process | Brushing Process
Brushing effects such as fine lines or spiral patterns can be made according to customer needs on the metal material surfaces. Fine lines are created with multiple sets of the same directional rotation of the friction wheel on the brushing machine brushing on the aluminum plate; spiral patterns are created by using grinding sheets in a rotational direction, polishing the surface of the sheet metal, this method is applied more on circular trademarks and small decorative pieces. Different effects on metal plate surfaces, once treated, have long shelf life; and can be matched with anodic oxidation treatment which is preferred for LCD TV back panel and front panel products. Screen Printing Process
Screen printing process is where stretched silk fabrics, synthetic fabric or metal mesh frame is put on the screen frame, then utilizing hand-engraved film or photochemical plate making to produce the screen printing plate. Modern screen printing technology uses photosensitive material through a photomechanical production of screen printing plate (on the silk screen with the graphic part of the mesh, the holes in the mesh are open; the holes in the other areas are closed). During printing, a scraper will squeeze the ink through the open mesh holes with the graphic part, transferring the ink to form the graphics. Screen printing equipment is simple, easy to operate, low cost, and very flexible. A wide range of common screen printing applications are: color oil paintings, posters, business cards, binding and cover, merchandise logos, and printing and dyeing textiles. Off-Set Printing Process
Off-set printing process is where the ink image is transferred (offset) from a plate to a rubber blanket, then to the printing surface. When used in combination with the lithographic process, which is based on the principle of oil and water repulsion, to make an image. Firstly, is to supply water to the non-image areas of the printing plate, to protect the images from being stained with ink, then during printing, provide ink supply to the image area of the printed plate. Finally, the transfer of ink to the canvas and then a rubber roller is rolled over it, leaving an impression of the desired images on the canvas. Lithography is an indirect printing. Pad Printing Process
Pad printing is the transfer of ink from the printing plate on to the printed material. The process begin by using photosensitive materials and through the photomechanical method produce the mesh plate, and then dip the soft rubber head with ink onto the graphics on the mesh plate, and finally print it on any kinds or types of materials. The difference between silk screen printing and pad printing is that pad printing is not limited to the plane of the object, even if the surface is curved, it can still create incredible effects. Cutting Process
Cutting process is to use a thin film that was previously formed fix into position on the male mold of the cutting die, clamp down on the mold and then remove the excess material, thus retaining the product’s 3D shape that matches with the mold cavity. Based on the effect dimensions and process requirements, our company is equipped with three categories; pneumatic press, hydraulic press, and extrusion punch. Engraving Process
The engraving process on the products’ surface can create formed lines with 3D effects on fonts or graphics. After the engraving process on the surfaces, the texture effects add beauty to the overall visual effects. This process is mainly used on copper and aluminum material nameplates. Die-Cutting Process-Punching
Die cutting process-punching uses thin film panel or line position as indicators onto bottom plate, position the blade onto the machine template, and taking advantage of the power and pressure of the machine to provide control of the blade to cut the material. The difference between this method and die cutting process-trimming is that, punching gives more smooth incision; and at the same time, indentation and half cutting down effect can be achieved due to the controlled pressure. Operational costs of the mold are low, and it is more convenient, safer, and faster. Die-Cutting Process-Trimming
Die cutting process-trimming use a thin film that was previously formed or assembled, using its line position to fix into position on the male mold of the cutting die, clamp down on the mold and then remove the excess material, thus retaining the product’s 3D shape, and match with the mold cavity. Based on the effect dimensions and process requirements, our company is equipped with three categories; pneumatic press, hydraulic press, and extrusion punch. CNC Process
CNC process is short for computer numerical control machine tools (Computer numerical control), the movements of the CNC machine tools are all inputted as data into the CNC device, thus directing the spindle and work table to directly changing the shape of the product, dimensions, surface state, and etc. all to meet the design requirements. CNC products are characterized by the machining operation standardization and the unified product quality. IML Process
The IML process is whereby the film is heated until it softens, then using an external force to shape the film during cooling, once cooled it will have the 3D effect. The external forces are: hot pressing and forming. PE Doming Process
PE doming process on a product is where two kinds of plastic are mixed together and coating is added to present the clear crystal effect on the surface of the product. The main function is to increase the surface effects, overall doming, local doming, and font shape doming effect, filling effect, partial filling effect, and weight control filling effect. Injection Process
Injection molding process is where the plastic material is melted and then injected into the mold chamber. Once the molten plastic is injected into the mold, it will begin to cool and as it cools it will take the shape of the mold cavity. Before the IMD injection molding process begins, the mold positioning film needs to be clamped down, and then injection can start. Our company’s injection molding process uses imported equipment, tonnage, and systems from Japan. This process can manufacture all kinds of products, from small micro-touch buttons to large 32-inch LCD TV box. Spray Painting ProcessSpray Painting Process
Spray painting process is made by the use of a gun or atomizer disc and by means of pressure or centrifuge force to disperse the paint in a uniform and fine droplet onto the desired coating area on the object. Certain desired design patterns can be achieved by applying fixtures on the object prior to the process begins. Spraying operations have high efficiency in production and is suitable for production of artisanal and industrial automation. It has a wide range of application, mainly in areas such as metal, plastic, and etc. This process is today’s most popular way of painting method; our company’s spray painting operations environment is at the standard of 10K particle cleanroom Laser Engraving Process
Laser engraving process is where a laser beam is used to create variety of permanent markings on different types of surfaces. Marking effects are created by evaporation by exposing the surface material to deep substance or light energy to cause chemical changes and thus “carve” out the desired effects. Or the effects can be traced out by a light energy to burn the part of the material with the desired design and font. Its characterized by (1) within the marking area, can process fonts, graphics, text, and images; (2) permanent markings, not regression due to the environment (such as moisture, acid, alkaline atmosphere); (3) quality markings that unless come into contact with additional processing, would not be damaged; (4) efficiency; and (5) low processing costs. Hot Stamping Process
Hot stamping process’s principle is to use a hot-press transfer, through the process of pressure by heating the foil onto its surface layer and transfer the desired shapes and effects onto the object, forming special metallic effects. Hot stamping has a clear pattern, is beautiful, and has vibrant colors, durable, and etc., perfect for the finishing touch on labels. Furthermore, hot stamping is a dry process method; hence the hot stamping work piece can be immediately packaged and transported. Ultrasonic Welding Process
Ultrasonic welding process is the use of the high-frequency vibration wave transmitted to the surfaces of two objects to be welded and with pressure, the friction between the two surfaces are formed by the fusion between the molecular layers. Ultrasonic metal welding advantages: (1) the welding material does not melt, it is not fragile like metal. (2) After welding, there is good electrical conductivity, electrical resistant is very low or almost zero. (3) The requirements of the surface of the weld metal are low, oxidations or plating can be welded. (4) The welding time is short, does not require any flux, gas, or solder. (5) No welding sparks, environmentally safe. Welding Process
The welding process is where buttons and products are welded together after heating the material to its melting point to form a connection. Generally, this process will have a design early on for the welding jig and have it be prepared for welding the buttons and products together.
PVD Process
PVD is short for Physical Vapor Deposition, indicating under conditions of a vacuum, low-voltage, and high-current arc discharge technique, then conduct target evaporation on the material and gas to cause electrical discharges, and using the acceleration of the electric field, the evaporated substance will react with the product by depositing itself onto the workpiece. After PVD treatment, the film has higher levels of hardness, low coefficient of friction, good abrasion resistance, and chemical stability advantages, and etc. Our company is experienced with the PVD process technology and has two PVD lines, and has experience working with aluminum, nickel, chromium, tin, and a dozen other materials. Membrane Lamination Process
Membrane lamination process begins on the membrane panel after it has been printed, the lamination would laminate on all kinds of insulating spacers, automatically becoming a protective layer over various types of LED, resistor, Dome, and automatic terminal interfaces. Through automation equipment, assemble the electronic components onto the flexible printed circuit board, letting it have certain electrical properties. To ensure the stability of the membrane switch performance, each piece needs to go through more than 2 times of full inspection and more than 3 times of PQC sampling inspection. In addition, a comprehensive inspection of function on powering on machine, switch performance, resistance LED light brightness, and colors. Always performing and passing all these tests and inspections can let our clients rest assured with our products. Assembly Process
Assembly process is where before products are shipped a final check of inspections and assembly are performed to ensure that the shipment of products meet the inspection requirements. This process is particularly important for windows or the functional requirements of IMD pieces and also the environment in which this process takes place also have high standards. Our company meets these high standards by having a separate clean room with the cleanliness of 1000 levels. Utilizing the semi-automatic assembly line operations, we can perform inspection and equipping on semi-finished products, before they are moved into storage. When the assembly process is needed for the products, we have the most complete systems and experience with TP, LCD assembly, and etc., accepting customer’s assembly operations. Packaging Process
The packing process consists of each piece of product needs to go through more than 2 times of full inspection and more than 3 times of PQC sampling inspection by a professional staff to ensure the stability of the product quality. 100% inspection on the overall outer appearance and comprehensive color examination. Always performing and passing all these tests and inspections can let our clients rest assured with our products. Double Shot Injection Process
The double shot injection molding is a process that can have two different kinds of materials and color injected into molds to produce a plastic part that has two different colors. This process provides more practicality and aesthetics to the plastic than a traditional injection molding process can, the advantages are: IMD Injection Process
The IMD injection process is where a decorative printed punched film is placed between the injection mold and the resin film, and then they are integrally bonded with a curing technology.
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