Finishing and Assembly
Bindal Technopolymer Private Limited (BTPL) offers a number of post-molding and secondary manufacturing and finishing services, including:
- Pad printing
- Screen Printing
- Inserting
- Value-added assembly
- Automated assembly
- Hot Chamber Pressure Die Casting
- Custom packaging
The finishing and assembly process of plastic parts is done in following steps
- Trimming and Degating to remove excess material (flash) with cutters, CNC, laser trimming and more
- Surface Finishing
- Sanding/Polishing
- Vapor Polishing
- Texturing
- Painting/Coating (UV protection, scratch resistance).
- Ultrasonic Cleaning
- Quality Inspection of dimensional accuracy and surface quality with Callipers, CMM and Visual Inspection Systems
- Assembly Process- assembly of parts into functional units using screws, snap-fit joints and more… Mechanical and ultrasonic welding is employed
- Adhesive Bonding- Epoxy, UV-cured sealants and adhesives alongwith cyanoacrylate is used for bonding
- Heat Staking/Insertion- To embed threaded inserts
- Pad Printing or Laser Marking- for white labeling, adding logos, instructions and serial numbers on part surfaces
- Functional Testing like water flow test, strength tests, pressure test, moisture and chemical proof test along with electrical testing
- Packaging and Shipping-The finished products are cleaned, irradiated, labelled and packaged for distribution.
Let’s delve deeper into the process..
A. Finishing Process
– Trimming & Deflashing
(a) Manual cutting- using scissors and knives to trim off excess material
(b) CNC trimming- Trim excess material from complex parts with ultra precision
(c) Cryogenic Deflashing – Cooling of plastic part to low temperatures to make the flash brittle and get it removed.
(d) Tumbling- Parts placed in abrasive media and rotated to smoothen out edges
B. Surface Treatment
(a) Sanding/Buffing: Sanding removes rough edges and smoothens out surfaces to render shiny finish.
(b) Chemical Etching- Chemicals are used to treat plastic surfaces to render texture and patterns on the surfaces and are mainly used in decoration.
(c) Plasma Treatment- It is used to modify plastic part surface energy thereby improving its ability for adhesive bonding or coating.
(d) Flame treatment- Flame is used to increase surface energy ensuring better adhesion of paints or coatings.
C. Painting/Coating
(a) Spray painting- Allows employing colours of choice on plastic surfaces.
(b) Powder coating- Powder coats are electrostatically applied on the surface parts and then melted ( ensuring structural deformity doesnt take place/baking) for a smooth finish
(c) Electroplating- Electrolysis method used for applying chrome or nickel and to give a metallic finish alongwith increasing strength.
(d) UV Coating- Applied to protect plastic surfaces from scratches and degradation.
D. Printing/Labeling
- Pad Printing
- Screen Printing
- Laser Engraving
- Heat Transfer Printing
E. Welding & Bonding
- Ultrasonic Welding:Ultrasonic vibrations used to provide heat for welding
- Hot Plate Welding:Heated plate used for melting and bonding parts
- Solvent Bonding: Solvent is applied to dissolve a thin layer and create fused molten surface for bonding two parts.
- Adhesive Bonding:Epoxies, cyanoacrylates (super glue), and polyurethanes used for bonding plastic parts together.
2. Assembly Techniques
A. Mechanical Fastening with screws, snap-fit connections, rivets, clips and hinges.
B. Adhesive Bonding with epoxies, cyanoacrylate, acrylic adhesives, polyurethane adhesives and more….
C. Insertion of Metal Components
- Heat Staking
- Threaded Inserts
- Overmolding
E. Functional Testing & Inspection
- Dimensional Accuracy
- Fitting & Alignment:
- Strength & Durability Testing
- Surface Defects
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