BILLY KITTRIDGE PETE KNEPPER PLET 370 MOLD TEXTURING BILLY KITTRIDGE PETE KNEPPER PLET 370
PURPOSE Hide scratches Aesthetically pleasing Achieve desired feel Create higher Frictional Coefficients
OUTLINE How mold texturing is done Design Requirements Hazard Issues Costs & turn around times Conclusion
INTRODUCTION Been around since beginning of plastics industry More of an Art, not Science Extremely labor intensive Very little technological advances
ADVANTAGES Hide scratches Aesthetically pleasing Desired feel No-slip surfaces Inexpensive Low turn around time
DISADVANTAGES Ejection problems Flashing issues Parting line Shut-offs
METHOD Make master Apply film Touch up pattern Etch Clean up
CREATION OF MASTER Pattern is created using computer software Printed onto usable film Film is applied to magnesium plate Plate is etched Master is cleaned up
CAMERA
MAGNESIUM MASTER
PREPARATION Master coated in wax Tissue paper applied to master Pattern is transferred to tissue paper Sandblast mold Helps paper adhere to mold surface
PREPARATION CONT. Tissue paper applied to mold Paper moistened and removed Pattern touched up Mask mold Seal tape seams
TISSUE PAPER
APPLYING PATTERN
MASKING MOLD
MASKING MOLD
PATTERN TOUCH UP
Etching Acid determined based on material Method Acids & materials etch at different rates Method Full bath Spray Partial bath Etching stopped and depth checked multiple times
CLEAN UP Masking removed Sandblast mold to remove wax Packaged for shipping
DESIGN REQUIREMENTS Every .001” of etching requires 1.50 of draft for ejection Acid etches in X & Y directions Fine etch (.001”-.004”) Course etch (.012”-.030”)
HAZARD ISSUES Rubber suits, respirators, and safety glasses must be worn Acid is neutralized before being disposed of Samples must be taken to water co. monthly
COSTS & TIMES Complexity determines price Embossing Rolls – 3-4 Days Size is insignificant Embossing Rolls – 3-4 Days Molds – 1-2 Weeks
EXAMPLE
EXAMPLE
EXAMPLE
CONCLUSION Easy way to add value to plastic parts Relatively inexpensive