Surface Finish | Prototool https://prototool.com/de/category/surface-finish/ Prototool Offizielle Website Mon, 08 Jan 2024 03:42:53 +0000 de-DE stündlich 1 https://wordpress.org/?v=6.6 https://prototool.com/wp-content/uploads/2022/05/prototool-logo-small.png Surface Finish | Prototool https://prototool.com/de/category/surface-finish/ 32 32 Pulverbeschichtung vs. Lackierung bei der Oberflächenbehandlung von Prototypen https://prototool.com/de/powder-coating-vs-painting-in-prototype/ Mon, 08 Jan 2024 03:42:51 +0000 https://prototool.com/?p=17124 Powder Coating vs Painting in Prototype Surface Treatment
Prototool

Entdecken Sie die wichtigsten Unterschiede zwischen der Pulverbeschichtung und der Lackierung im Prototyp, einschließlich der Anwendungsmethoden, der Kosteneffizienz usw.

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Powder Coating vs Painting in Prototype Surface Treatment
Prototool

Spray coating encompasses spray painting, spray oiling, and spray zinc. In this context, spray painting and spray oiling are considered the same process and will be collectively referred to as spray painting. Powder coating, also known as plastic spraying, is a different process and will be referred to as powder coating in this article. Spray zinc, often used for large architectural steel structures or high-demand metal workpieces, will not be the focus of this discussion. Let’s talk about powder coating vs painting in prototype today.

Among all the surface treatment types mentioned, spray painting is arguably the simplest. It involves pouring paint into a specialized spray painting device and using a spray gun to coat the workpiece. The piece is then left to dry naturally or is dried using high heat. Thus, it’s a relatively straightforward physical process.

The equipment and techniques used in these processes vary, leading to differences in texture and cost.

Differences Between Spray Painting and Powder Coating

Let’s briefly outline their key differences:

Spray Painting vs. Powder Coating: Spray painting is a technique of dispersing liquid paint, commonly referred to as paint into fine dust particles which are blown on the surface of an object using compressed air. Powder coating, on the other hand uses compressed air to spray powder in a high-voltage electrostatic field. The powder particles are then drawn towards the surface of the object using an electric field.

The Correct Term for Powder Coating: Powder coating as a process is properly referred to as “electrostatic powder coating.” It’s not the sort of task that can be accomplished using just an ordinary spray paint gun. Equipment for powder coating comprises a powder supply barrel using compressed air, a High-voltage electrostatic generator and an electrostatic spray gun. Outdoor and indoor powders are the plastic powder used in this process. The main kind is Outdoor powder made ​​of epoxy resin, which in terms of composition differs fundamentally from the paint.

Powder Coating process for Prototype

Analysis of Characteristics For Comparing Powder Coating vs Painting

Powder Coating Process

1. No Solvents in Powder Coatings:

Powder coatings do not contain any solvents and are 100% solid. This aspect addresses pollution issues caused by solvents during manufacturing, transportation, storage, and application. It improves the working conditions for operators and benefits their health.

2. Simplified Coating Process:

The powder coating process involves just three steps: spraying the powder, curing, and cooling, allowing for a one-step film formation. This simplicity significantly streamlines the coating process, shortens the production cycle, and enables product output on the same day. In electrostatic powder coating, the integration of automatic coating machinery and a recycling system can lead to automated production, saving energy and resources and enhancing productivity.

3. High Utilization Rate of Powder Coatings:

Powder coatings can be directly applied to the surface of the object and cured by baking to form a coating. Unused powder can be collected and reused, with a utilization rate of over 95%.

4. Durable and High-Performance Powder Coatings:

Powder coatings can be made from resins that are insoluble at room temperature or high-molecular-weight resins that cannot be liquefied. This results in high-performance coatings with various functionalities. The absence of solvents in the preparation or film formation process prevents pinholes in the coating, making it denser.

5. One-Time Coating Possibility:

A single application of powder coating can achieve a film thickness of 50 to 300 μm without the dripping or sagging issues common with thick paint applications. It also avoids solvent pinholes and defects associated with thick film coatings, and offers high edge coverage. In contrast, paint typically requires multiple applications to achieve a similar thickness or quality.

6. Challenges in Color Changing:

Unlike paint, which can be mixed on-site, the color of powder coatings is predetermined at the factory. Changing the color requires altering the powder coating formula, making quick color changes challenging. Electrostatic spraying necessitates thorough cleaning of the spray gun, powder feeder, spray chamber, transport pipes, and recycling system during color changes, especially when switching between dark and light colors.

7. Difficulty in Achieving Thin Films:

Due to the principles of electrostatic spraying, the thickness of powder coatings is generally above 50 μm. Even with high-quality powder coatings and optimal conditions, achieving a film thickness below 40 μm is challenging.

8. Slightly Inferior Surface Smoothness:

Powder coatings, which rely on heat-induced melting and leveling on the object, have a higher melting viscosity. This can result in a slightly orange-peel texture, making the coating less smooth than paint.

9. Certain Limitations:

The limitations of the powder coating process are mainly in three areas: First, since the curing temperature of powder coatings is generally above 160°C, this restricts their use on heat-sensitive products like plastics. Second, as most powder coating processes use electrostatic spraying, the object must be conductive. Non-metallic objects require conductive treatment and must withstand temperatures above 160°C.

Powder Coating Prototype Case

Spray Painting Process

1. Wide Variety of Paints:

China categorizes paints into seventeen major types, with thousands of varieties available, and new types are continually emerging. Users can select the most suitable paint based on product performance, usage, and environmental factors to achieve optimal coating results.

2. Comprehensive Process Techniques:

Spray painting adapts well to various methods, including brush painting, dip coating, flow coating, roller coating, knife coating, air spray painting, high-pressure airless spray painting, electrophoretic painting, and electrostatic spray painting. Among these, brush painting, air spray painting, and electrophoretic painting are widely used.

3. Lower Initial Equipment Investment:

Spray painting equipment mainly includes spray guns, air compressors, oil-water separators, and necessary air hoses. Compared to the substantial investment required for powder coating equipment, spray painting involves less initial capital, lower production costs, and quicker capital recovery.

4. Simplified Pre-treatment Process:

In spray painting, thanks to the excellent rust-prevention properties of primers and their good adhesion to both substrates and topcoats, the corrosion resistance of the coating is significantly enhanced, ensuring the longevity of the coating. Only degreasing and derusting treatments are needed before applying the primer, thereby simplifying the pre-treatment process, saving production costs, and improving efficiency.

5. Longer Production Cycle and Higher Overall Cost:

Spray painting involves more steps than powder coating. During application, it requires the use of primers, putties, thinners, and topcoats, with drying time needed between each step. Some paints also require heat drying. Therefore, considering material consumption, energy use, and labor costs, the overall cost of spray painting is higher than powder coating, and the production cycle is longer.

6. Poor Environmental Performance:

Harmful to Operators’ Health: Paints contain organic solvents that can volatilize into the air during application and curing. Air spray painting produces a significant amount of overspray and paint mist, which is harmful to health, necessitating the use of protective masks by operators.

7. Higher Fire Hazard Compared to Powder Coating:

Spray painting poses a higher fire risk than powder coating for several reasons: First, the organic solvents in paint are highly volatile and can easily ignite or explode upon contact with open flames or sparks. Powder coatings do not contain organic solvents, thus presenting a lower risk. Second, the flash point, ignition point, and ignition energy of paint are lower than those of powder coatings, leading to faster combustion spread. Lastly, the ventilation equipment, working environment, and operational procedures in air spray painting are generally less advanced than in powder coating, increasing the risk of fire.

It’s important to note that while spray painting has a higher fire risk than powder coating, in the rare event of an explosion, the intensity and destructive power of a powder coating explosion can be much greater than that of liquid paints.

Painting Prototype Case

Powder Coating vs Painting Overall Comparison

Environmental Impact: Powder coating is often seen as being less detrimental to the environment than standard spray painting. It emits lesser amounts of volatile organic compounds (VOCs) that are harmful to human health and the environment.

Durability and Finish: Generally powder coating gives a thicker and more even finish than spray painting. It is more resistant to chipping, scratching and other wear and tear making it great for items requiring a hard finish.

Application Efficiency: Powder coating is more efficient in the application process. Extra powder can be salvaged and reused, thereby reducing wastage. However, spray painting tends to result in overspray and will require more accuracy for an even finish.

Curing Process: Powder coating curing process is faster compared to traditional spray painting. Heating allows for cure-coated items to be ready much faster.

Kostenüberlegungen: Although this initial setup cost for powder coating can be more due to the equipment needed it will actually work out cheaper in ring term because of its efficency, life span and lower waste.

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Annealing Plastic: The Essential Process for Optimal Product Quality https://prototool.com/de/annealing-plastic/ Sun, 08 Oct 2023 03:26:53 +0000 https://prototool.com/?p=14392 Annealing Plastic: The Essential Process for Optimal Product Quality
Prototool

Learn the significance of annealing plastic manufacturing. Click to partner with experts to enjoy Prototool's top-tier injection molding.

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Annealing Plastic: The Essential Process for Optimal Product Quality
Prototool

In the vast world of plastics manufacturing, one process stands out as crucial for ensuring product longevity and quality: annealing plastic. This technique, often overlooked, plays a pivotal role in addressing the inherent challenges faced during the molding and formation of plastic parts. Whether it’s about achieving uniform crystallization, mitigating internal stresses, or enhancing the overall mechanical properties, the annealing process is the unsung hero. As we delve deeper into the intricacies of plastic annealing methods, plastic annealing temperature, and the reasons behind annealing plastic molded parts, it becomes evident how this procedure is a cornerstone in the realm of plastics.

The Imperative of Annealing in Addressing Internal Stresses in Plastics

Plastics, versatile and ubiquitous, undergo various processes during their formation. However, during these processes, certain challenges arise. One of the primary challenges is the uneven plasticization within the barrel or inconsistent cooling rates within the mold cavity. This inconsistency often leads to uneven crystallization, orientation, and shrinkage in the final product. As a result, the product harbors internal stresses, which become particularly pronounced in thick-walled products or those with embedded parts.

The presence of these internal stresses is not just a theoretical concern. In practical terms, they manifest in tangible ways. When a product with internal stresses is stored or used, its mechanical properties deteriorate. This degradation is evident through visible surface defects, such as silver streaks, and in severe cases, can even lead to deformation or cracking of the product.

The Consequences of Ignoring Internal Stresses

Ignoring these internal stresses isn’t an option. They compromise the integrity, aesthetics, and functionality of the plastic product. Whether it’s a subtle surface imperfection or a more pronounced structural flaw, the repercussions can be significant, especially in applications where precision and durability are paramount.

Annealing as the Optimal Solution

In the realm of plastic manufacturing, addressing these internal stresses is paramount. And the most effective method to combat these stresses? Annealing plastic molded parts. By undergoing the annealing process, these stresses are alleviated, ensuring the product retains its desired properties and aesthetics. It’s not just about fixing a problem; it’s about elevating the quality of the product to meet the highest standards.

The Intricacies of the Annealing Process for Plastics

The annealing process, while seemingly straightforward, involves a meticulous approach to ensure the desired outcomes. It’s not just about heating and cooling; it’s about understanding the nuances that make the difference between a successful annealing and a subpar one.

The Annealing Procedure

At the heart of plastic annealing lies the method. The product is placed in a constant temperature heating liquid medium, such as hot water, mineral oil, glycerin, ethylene glycol, or liquid paraffin. Alternatively, a hot air circulation box can also be used. After a specified duration, the product is then cooled slowly to room temperature. The heat during the annealing process accelerates the relaxation of the large molecules within the plastic. This relaxation is pivotal in eliminating or reducing the residual stresses that form post-molding.

Temperature Considerations in Annealing

Temperature plays a critical role in the annealing plastic molded parts process. The annealing temperature is typically controlled to be 10-20°C above the product’s usage temperature or 10-20°C below the plastic’s heat distortion temperature. But there’s a fine line to tread. If the temperature is too high, the product might warp or deform. Conversely, if it’s too low, the annealing might not achieve its intended effect.

Time and Other Factors in Annealing

The duration of annealing isn’t arbitrary. Several factors, including the type of plastic, the temperature of the heating medium, the shape and thickness of the product, and the precision requirements of the product, determine it. The goal is clear: to effectively eliminate internal stresses. Once the annealing is complete, the cooling process begins. But caution is needed here, too. Cooling too rapidly might reintroduce those unwanted internal stresses. For thin-walled products, the cooling rate should be around 50-60°C/h, while for thicker products, it should be less than 10°C/h.

Annealing Conditions for Different Plastics

Understanding the specific annealing conditions for various plastics is crucial for achieving optimal results. The table below provides a comprehensive overview of the annealing conditions tailored for each type of plastic:

Plastic NameTreatment MediumProduct Thickness (mm)Annealing Temperature (°C)Processing Time (min)
ABSWater or Air60~7516~20
PSWater or Air≤660~7030~60
>670~77120~360
PMMAAir7516~20
POMAir2.516060
Oil2.516030
PPAir≤315030~60
4~660
HDPEWater≤610015~30
>660
PCOil or Air1120~13030~40
3120~130180~360
>6130~140620~960
PETNitrogen-filled furnace3130~15030~60
PBTNitrogen-filled furnace3130~15030~60
PA6Water>610025
PA66Oil3~613020~30
Water: Potassium Acetate (1:1.25)3~6100120~360
PA1010Water6100120~360
PPOOil or Air3~6120~14060~240

Determining the Need for Annealing in Plastic Products

While the annealing process offers numerous benefits, it’s essential to recognize that not all plastic products require this treatment. The decision to anneal often hinges on specific characteristics of the plastic and the intended application of the final product.

Criteria for Annealing Plastic Products

Certain attributes and conditions necessitate the annealing of plastic molded parts. Typically, products made from plastics with rigid molecular chains, thicker walls, metal inserts, a wide temperature usage range, high dimensional accuracy requirements, and significant internal stresses that don’t dissipate easily should undergo the annealing process. These factors combined can compromise the product’s integrity, making annealing not just beneficial but essential.

Exceptions to the Rule

Conversely, some plastics might not need the plastic annealing process. Products made from plastics with inherently flexible molecular chains and lower glass transition temperatures, such as polyoxymethylene and chlorinated polyether plastics, fall into this category. While these products might harbor internal stresses, these stresses can dissipate slowly on their own. If the product doesn’t have high-temperature usage requirements, it might be best to forgo the heat treatment.

Trusting Prototool for Excellence in Plastic Manufacturing

In the intricate world of plastic manufacturing, understanding and implementing processes like annealing is paramount. At Prototool, we pride ourselves on our deep-rooted expertise in plastic products and parts manufacturing through the injection molding process. Our longstanding collaboration with trusted suppliers for annealing treatments ensures that every product we craft meets the highest standards of quality and durability. As you navigate the complexities of the plastic industry, let Prototool be your trusted partner, bringing unparalleled knowledge, experience, and dedication to every project.

The post Annealing Plastic: The Essential Process for Optimal Product Quality appeared first on Prototool written by Prototool.

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Metal Anodizing CNC Machined Parts – A Brief Guide https://prototool.com/de/metal-anodizing/ https://prototool.com/de/metal-anodizing/#respond Sun, 13 Aug 2023 11:33:41 +0000 https://prototool.com/?p=12803 Metal Anodizing CNC Machined Parts – A Brief Guide
Prototool

Metal anodizing is a popular technique in the engineering and maker communities. It’s well-known for improving the strength, durability, and lifetime of machined components, making it a vital technique in the manufacturing process. Aside from these advantages, anodizing has several advantages that make it important for producing high-quality parts. Anodizing should be a top priority […]

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Metal Anodizing CNC Machined Parts – A Brief Guide
Prototool

Das Eloxieren von Metallen ist ein beliebtes Verfahren in der Technik- und Herstellergemeinschaft. Es ist dafür bekannt, dass es die Festigkeit, Haltbarkeit und Lebensdauer von maschinell bearbeiteten Bauteilen verbessert, was es zu einer wichtigen Technik im Herstellungsprozess macht.

Abgesehen von diesen Vorteilen hat das Eloxieren mehrere Vorteile, die es für die Herstellung hochwertiger Teile wichtig machen.

Das Eloxieren sollte oberste Priorität haben, wenn es darum geht CNC-Bearbeitung Arbeitsplätze. Dieses Verfahren erzeugt eine harte und dauerhafte Oberfläche auf den bearbeiteten Gegenständen und garantiert, dass sie den harten Bedingungen des täglichen Gebrauchs standhalten können.

Wenn Sie das Eloxieren in Ihren Fertigungsprozess einbeziehen, können Sie Bauteile herstellen, die nicht nur fantastisch aussehen, sondern auch unglaublich gut in einer Vielzahl von Anwendungen funktionieren. Wenn Sie möchten, dass Ihre CNC-Bearbeitungsprojekte stabil und langlebig sind, ist Eloxieren ein notwendiger Schritt.

In diesem Artikel gehen wir auf den Prozess des Eloxierens von Metall ein und erläutern, was das Eloxieren von CNC-gefrästen Teilen zu einer effektiven Methode macht. Lesen Sie weiter, um alles darüber zu erfahren.

Lesen Sie auch: Analyse des Auftretens von Schweißnähten beim Spritzgießen und deren Lösungen

Metall-Eloxalverfahren für Fertigprodukte

Wie macht das Eloxieren von CNC-Maschinenteilen einen Unterschied?

Angesichts der wachsenden Beliebtheit und Nachfrage nach der Eloxierung von Metallteilen auf CNC-Maschinen ist es wichtig zu wissen, wie sich dies auf die Qualität und Leistung dieser Teile auswirkt. Im Folgenden finden Sie eine detaillierte Analyse dieser Faktoren:

Stärke und Langlebigkeit

Das Eloxieren trägt wesentlich dazu bei, die Festigkeit und Beständigkeit der CNC-gefrästen Teile zu erhöhen. Das Eloxalverfahren führt zu einer Oberfläche, die sowohl härter als auch verschleißfester ist und diese Komponenten besser vor Verschleiß schützt.

Durch dieses Verfahren gewinnen die CNC-gefrästen Teile an Festigkeit, so dass sie auch anspruchsvollen Bedingungen standhalten. Dadurch können sie ihr makelloses Aussehen und ihre strukturelle Integrität auch nach langer Zeit der Nutzung beibehalten.

Die Eloxierung bietet nicht nur einen besseren Schutz gegen Korrosion und Verschleiß, sondern trägt auch zur Langlebigkeit dieser Bauteile bei, so dass sie über ihre gesamte Lebensdauer hinweg hervorragende Leistungen erbringen.

Mit der Eloxierung können Ingenieure und Hersteller Vertrauen in die Zuverlässigkeit und Langlebigkeit der von ihnen hergestellten CNC-gefrästen Teile schaffen.

Lesen Sie auch: Hauptspindel in CNC-Maschinen: Definition, Funktion, Typen, & Kaufberatung

Korrosionsbeständigkeit

Das Eloxieren erhöht den Schutz und die Verschleiß- und Korrosionsbeständigkeit von CNC-gefrästen Bauteilen. Diese erhöhte Langlebigkeit ist besonders wichtig, wenn die Teile in rauen Umgebungen eingesetzt werden oder extremen Bedingungen ausgesetzt sind.

Im Vergleich zu nicht eloxierten Bauteilen sind eloxierte Bauteile korrosionsbeständiger und können den Witterungseinflüssen wesentlich länger standhalten. Darüber hinaus sind eloxierte Oberflächen viel glatter und härter als unbehandelte Oberflächen, was die Wärmeableitung fördert und die Gesamtlebensdauer des Bauteils erhöht.

Infolgedessen kann das Eloxieren dazu beitragen, die Lebensdauer von CNC-gefrästen Teilen zu verlängern und die Leistung dieser Teile im Laufe der Zeit zu maximieren. Generell ist das Eloxieren eine hervorragende Methode, um Korrosion und andere Formen der Beschädigung von CNC-gefrästen Teilen zu verhindern.

Dank dieses verbesserten Schutzes sind die Hersteller nun in der Lage, qualitativ hochwertigere Produkte zu entwickeln, die länger halten als in der Vergangenheit, und dabei langfristig Geld für Reparaturen und Ersatz zu sparen.

Chemische Beständigkeit

Im Allgemeinen ist das Eloxieren als Verfahren bei der Herstellung von CNC-gefrästen Teilen hilfreich. Die Technik bietet nicht nur Korrosionsbeständigkeit, sondern auch einen besseren Schutz und eine längere Lebensdauer. Diese Methode bietet alle drei Vorteile.

Im Folgenden werden die drei wichtigsten Vorteile des Eloxierens genannt, die zu seiner großen Beliebtheit beitragen:

  • Durch das Eloxieren entsteht auf der Oberfläche des Metalls eine harte Schicht, die es vor Abrieb und Verschleiß schützt.
  • Es beseitigt alle kleinen Poren, die möglicherweise auf der Metalloberfläche vorhanden waren, und verhindert so die Ansammlung von Feuchtigkeit und die anschließende Bildung von Korrosion.
  • Im Vergleich zu nicht eloxierten Komponenten weisen eloxierte Teile eine höhere Festigkeit und Haltbarkeit auf, was sie zu einer ausgezeichneten Wahl für stark beanspruchte Anwendungen macht, bei denen Zuverlässigkeit von größter Bedeutung ist.
  • Das Eloxieren ist eine effiziente Methode, um die Lebensdauer von CNC-gefrästen Teilen zu verlängern und sicherzustellen, dass sie auch in rauen Umgebungen in bestmöglichem Funktionszustand bleiben. Aufgrund seiner außergewöhnlichen Fähigkeit, Korrosion zu verhindern, erweist es sich als eine hervorragende Wahl für eine Vielzahl von Anwendungen, bei denen Langlebigkeit von großer Bedeutung ist.
  • Darüber hinaus erfordert die Methode nur sehr geringe laufende Wartungskosten, was ein weiterer Faktor ist, der zu ihrer allgemeinen Attraktivität beiträgt.

Lesen Sie auch: Vergleich von Elektrodenbearbeitungsprozessen für verschiedene Materialien: Wie funktioniert es?

Ästhetische Anziehungskraft

Das Eloxieren, ein Verfahren, das bei der Herstellung von CNC-gefrästen Teilen zum Einsatz kommt, hat mehrere ästhetische Vorteile und ist daher eine ideale Wahl zur Verbesserung der optischen Attraktivität von Komponenten.

Das Verfahren erzeugt faszinierende Farbveränderungen und ermöglicht es, die bearbeiteten Teile mit einer vielfältigen Farbpalette zu versehen. Darüber hinaus wird durch das Eloxieren eine Schutzschicht erzeugt, die die Haltbarkeit und Korrosionsbeständigkeit erhöht.

Dadurch wird sichergestellt, dass die Teile nach Abschluss des Verfahrens noch lange Zeit ihr ansprechendes Aussehen behalten. Trotz der zusätzlichen Kosten sind die bemerkenswerten Ergebnisse und die verlängerte Lebensdauer eine lohnende Investition.

Dauerhaftigkeit

Eloxieren ist die beste Lösung, wenn Sie etwas suchen, das lange hält. Durch die Bildung einer Schutzschicht auf der Oberfläche der Bauteile wird deren Haltbarkeit erhöht, was wiederum die Wartung vereinfacht und die Leistung insgesamt verbessert.

Die Investition in die Eloxierung der CNC-gefrästen Teile stellt sicher, dass diese so konstruiert sind, dass sie dem Test der Zeit standhalten und somit kein häufiger Austausch oder Wartung erforderlich ist.

Wer auf der Suche nach zuverlässigen und langlebigen Bauteilen ist, kann das Eloxieren in Betracht ziehen, weil es die Vorteile von Schutz und Ästhetik vereint.

Schutz vor den Auswirkungen von Korrosion

Das Eloxieren verbessert nicht nur die Ästhetik des Artikels, sondern bietet auch einen erheblichen Schutz gegen Korrosion.

Durch diese vorbeugende Maßnahme behalten die CNC-gefrästen Teile ihr makelloses Aussehen für einen wesentlich längeren Zeitraum.

Die einfache Wartung, die mit eloxierten Oberflächen verbunden ist, minimiert auch den Bedarf an regelmäßiger Wartung oder häufigem Austausch, was zur Kostenwirksamkeit und Effizienz des Produkts beiträgt.

Das Eloxieren ist zweifellos die Methode der Wahl, wenn es darum geht, Bauteile mit dem höchstmöglichen Korrosionsschutz auszustatten und gleichzeitig ihr ästhetisches Erscheinungsbild zu verbessern.

Vorgeschlagene: Warum ist die CNC-Entformung besser als die manuelle Entformung?

Prototool's Metal Anodizing ways
Prototools Wege zur Eloxierung von Metall

Positive Auswirkungen auf die Umwelt

Die Verwendung von Eloxal bei der Herstellung von CNC-gefrästen Teilen kann erhebliche positive Auswirkungen auf die Umweltqualität haben.

Die Abfallerzeugung wird wirksam reduziert, was zu einem umweltfreundlicheren Herstellungsprozess beiträgt. Durch die Verringerung des Abfallaufkommens können die Produktionskosten des Teils erheblich gesenkt werden, wodurch sich auch die inhärente Kosteneffizienz des Artikels verbessert.

Darüber hinaus führt das Eloxieren zu Energieeinsparungen und trägt damit wesentlich zur Verringerung des Kohlenstoffabdrucks bei, den der Herstellungsprozess hinterlässt.

Anodizing offers several important advantages for the environment, including the following:

Reduced Waste:

Anodizing assists in employing less materials during production, which results in decreased waste formation. This is one of the benefits of anodizing. This waste reduction is in line with sustainable principles and helps to limit the impact that the manufacturing process has on the surrounding environment.

Reduced Emissions:

Conventional methods frequently result in the release of emissions that add to the problem of environmental pollution. The process of anodizing helps reduce these pollutants, which results in a production method that is cleaner and more environmentally friendly.

Energy Efficiency:

The process of anodizing results in less energy being consumed, which in turn lowers both the cost of energy and the amount of energy that is used overall. As a consequence of this, it not only improves energy efficiency but also cuts down on production times and raises the overall quality of the output.

Anodizing provides various benefits to the environment while preserving reliable performance; as a result, businesses that want to achieve cost-effectiveness and environmental responsibility in their manufacturing processes are increasingly turning to anodizing as a means to accomplish these goals.

Lesen Sie auch: CNC-Gewindebearbeitung 101: Was ist das und wie funktioniert es?

Easy Maintenance:

One of the primary benefits of anodized metal parts is the ease with which they can be maintained, which is a significant factor in the widespread adoption of these components across a variety of business sectors.

The process of anodizing generates a protective layer on the surface of the metal, which results in the parts having increased resistance to wear and tear, as well as corrosion and fading.

This protective coating makes the maintenance process a substantial amount simpler, resulting in cost savings and greater longevity of the parts.

Anodized metal parts are notoriously low-maintenance, and the following are some of the reasons why:

Cleaning:

Mild soap and water are all needed to clean anodized metal parts, making routine maintenance a breeze and eliminating any hassles. Because the anodized surface is resistant to stains and does not trap dirt, cleaning it is simplified for applications that are used indoors and outdoors.

Scratch Resistance:

The anodizing process creates a hard surface, which has good scratch resistance properties. It is less likely that the appearance or performance of the parts will be affected by minor scratches or scuffs, making the parts more durable and reducing the frequency with which they need to be touched up.

Resistance to Corrosion:

The anodized layer provides this resistance by acting as a barrier against corrosion and protecting the underlying metal from oxidation. Due to the material’s resilience to corrosion, specialist anti-corrosion treatments and regular maintenance are no longer required to keep the material from rusting.

Color Stability:

Anodized metal pieces don’t lose their color or look with time; instead, they keep their distinctive finish. Even after extended exposure to harmful UV rays and harsh climatic conditions, the color of anodized components does not change or peel, in contrast to painted or coated surfaces, which can lose their luster over time.

Reduced Wear:

The protective coating of anodizing helps reduce the amount of wear on the metal surface, particularly in situations with a lot of friction. This decrease in the need to replace worn parts reduces the costs linked to maintenance.

Resistance to Chemicals:

Anodized metal components have excellent resistance to various chemicals, including alkalis and acids. Because of its chemical resistance, the material is easier to handle and maintain, making it suitable for use in settings where there is a risk of being exposed to corrosive substances.

Low Maintenance Products:

Products and equipment with anodized parts typically need the least care compared to other finishes. This results in enhanced operational efficiency and minimizes the downtime required for maintenance, which benefits many industries, including the automotive, aerospace, and marine sectors.

Longer Lifespan:

Anodized metal parts have a longer lifespan than untreated metal parts because they are easier to maintain. The parts maintain excellent condition and continue to work reliably for significantly longer periods due to reduced wear, corrosion, and color deterioration.

In general, the fact that anodized metal parts are so simple to clean and maintain makes them a desirable option for a wide variety of applications.

The protective features of anodizing not only make cleaning and maintenance much easier but also help the general performance and longevity of the parts, making it more likely that they will continue to be in pristine condition for many years to come.

 Anodizing CNC Machine Parts with Prototool:

Prototool provides a full range of CNC machining and fast prototyping services, including metal anodizing. Prototool collaborates with a sibling firm that operates an anodizing plant with over ten years of experience after manufacturing the CNC machine parts.


To create a protective anodized layer, we submerge the metal parts in an electrolytic solution and apply an electric current. This stage improves the items’ durability, corrosion resistance, and aesthetic appeal, completing the surface treatment process.

Prototool ensures clients receive high-quality, fully-finished CNC machined components adapted to their demands by combining anodizing services. The ten years strong partnership with an anodizing facility, which is Prototool’s sister company, enables us exact control over the anodized layer thickness and color options, resulting in personalized and efficient solutions to clients’ individual needs.

Customers can streamline their manufacturing process by utilizing our professional experience in CNC machining and anodizing, resulting in top-notch CNC machined products with excellent surface characteristics.

Lesen Sie auch: Warum sollten Sie CNC-Prototyping in Betracht ziehen? Nutzungsanforderungen, Einschränkungen und Expertentipps

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Surface Finishing: Common Types And Important Factors To Consider https://prototool.com/de/surface-finishing/ https://prototool.com/de/surface-finishing/#respond Mon, 26 Sep 2022 01:57:53 +0000 https://prototool.com/?p=6188 Surface Finishing: Common Types And Important Factors To Consider
Prototool

When determining whether or not a product is of good quality, attention to detail in its surface finishing is crucial. The surface finish is often the last step in the production process, regardless of the material used. There are numerous appliances, pieces of equipment, and other objects we interact with daily, and many of them […]

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Surface Finishing: Common Types And Important Factors To Consider
Prototool

When determining whether or not a product is of good quality, attention to detail in its Oberflächenveredelung is crucial. The Oberflächengüte is often the last step in the production process, regardless of the material used. There are numerous appliances, pieces of equipment, and other objects we interact with daily, and many of them have finished surfaces or need components with a surface finish. Therefore, these procedures are often required in all companies.

one of the surface finishing method laser carving

Multiple surface machining methods exist for improving a substrate’s surface, but they all have the same result. In this way, the material’s surface becomes more uniform and uniform in texture. However, corrosion and wear resistance, Oberflächentextur, coloringund Beschichtung are all factors in how these various procedures influence the surface of a product. Thus, each one has its unique features and applications.

Choosing among the various surface finishing techniques for a given product is difficult. This complete guide on surface finishing has been produced to make your life as straightforward and stress-free as possible. Read on to learn about the nuances between finishes and how different vendors may operate.

What is Surface Finishing?

Surface finishing encompasses various manufacturing procedures that enhance a product’s visual appeal, mechanical properties, and other qualitative characteristics. They transform the substance by including new elements, changing the makeup of existing ones, removing part of it, or molding it in a new form. Mechanical, chemical, or electrical processes often accomplish these responsibilities.

The surface finish may be achieved in many ways, but at its heart, it is the process of altering the surface of an object (or substrate) to obtain the desired quality. Depending on a number of circumstances, one’s final surface quality requirements may vary significantly.

Why Is There A Need For Surface Finish?

The amount of Oberflächengüte may affect the functionality of the device. When you need to assemble two pieces, you’ll want to locate a relatively smooth surface so they can fit together. When working with a vendor to produce components, the vendor must employ materials that add to the functioning of the element. There is considerable variance in surface finishes; thus, you must ensure that the finish is just right.  

Following are some of the reasons why Oberflächenveredelung is opted for so frequently:

  • Protection against corrosion is improved
  • Assisting in the bonding of various coatings
  • Damage to the surface is repaired.
  • Elevated Immunity to Chemicals
  • Enhanced conductivity and enhanced electrical conduction at the surface
  • Superior durability and wear resistance with less frictional impacts
  • The improvement of aesthetics

Types Of Surface Finishing

Surface Finishing Room

It’s possible to observe the Oberflächengüte from two perspectives at once. From the designer’s perspective, a part’s performance might be affected by the part’s surface quality. From the machinist’s point of view, surface finish is the end result of the procedures used and may be altered by changing those processes.

The Following processes are defined under the following two methods:

  • Adding or Altering Process
  • Removing and Reshaping Process

Electropolishing

Electropolishing is similar to electroplating in that both processes include the use of electricity and chemical reactions; however, in electropolishing, ions are removed from the surface being treated, while in electroplating, ions are added to the surface. Electropolishing is a typical procedure for deburring and lowering average surface roughness to obtain a smooth, level, and flaw-free surface. Metals such as stainless steel, aluminum, copper, titanium, nickel, and copper alloys are often electropolished. This method is particularly beneficial for metals in the food, medicinal, and pharmaceutical sectors.

Malerei

Engineers often demand painting as a surface treatment to improve a product’s aesthetic and corrosion resistance. Spray painting, electrostatic painting, dipping, brushing, and powder coat paint are the most popular techniques for applying paint to the surface of a component. An alternative is to paint using a powder coat.

Metal components may be protected against a wide variety of environmental conditions by using any of a number of different paint formulas. The automobile industry has completely mechanized and mechanized the process of painting cars and trucks, using hundreds of robot arms to achieve remarkably consistent results.

Sanding or Sand Blasting

These surface finishing procedures need relatively basic tools and equipment, but the personnel engaged must have a high degree of skill since they are primarily done manually. Automation developments have lowered the amount of required human labour, boosting the output’s dependability and consistency.

A surface layer is removed or changed in this kind of operation utilizing a variety of machining processes known collectively as abrasive machining. This procedure eliminates dry or wet surface imperfections from metal depending on the circumstances (using oils, water, or other liquids).

Abrasive machining processes are often required for metals such as aluminum, brass, cast iron, carbon steel, and stainless steel. Lapping is often used to manufacture optical lenses, bearings, and other components that need fine finishes and great accuracy.

Electroplating

All kinds of electroplating include using electricity to drive an electric current through a bath of liquid to plate metals. The substrate is then treated substance, while the bath is a solution containing ions of the metal being added.

The substrate serves as a cathode when an electric current is delivered through it. It enables it to attract ions from the bath, which are then deposited on the treated surface. Higher durability, increased corrosion resistance, less surface friction, and improved aesthetics are a few benefits of this method.

 This method treats zinc, nickel, copper, gold, silver, and other metals. However, we may use this process to cure almost any other metal.

Vacuum Plating

Using a high vacuum at some point in the plating process is one of the most used methods for metal surface finishing. These processes include sputtering, ion plating, nitriding, and implantation. Another prevalent method is vacuum vapor deposition.

A highly regulated environment is required to produce ionized metals, oxides, and nitrides. Subsequently, the component is put in the vacuum chamber and prepared for the metal deposition technique, executed with outstanding precision. Titanium nitride is a surface treatment that increases the service life of high-carbon steel or carbide-cutting tools.

Thermal Spraying

In this kind of surface treatment, components are first heated or melted, then accelerated, and finally collide with one another before being mechanically attached to the desired surface. In order to dissolve a wire or powder feedstock, which is often composed of metal or ceramic, it must first be introduced into a flame, an electrical arc, oder a plasma stream.

On occasion, engineers may specify this method when a greater coefficient of friction is needed. In addition, it is often applied to more significant structural elements to give protection from high temperatures, such as a thermal barrier coating for exhaust heat management.

Chemical Treatment

This method uses chemical reactions to create thin layers of sulfide and oxide. Metals can be colored, corrosion might be prevented, and surfaces could be primed for subsequent paint applications. Black oxide is one of the most common surface treatments for steel parts, and “passivation” is the process that removes free iron from the surface of stainless steel components.

Powder Coating

Pulverbeschichtung uses static electricity to put a dry powder on a surface. After the powder has been electrostatically deposited, the metal component is heated to “melt” the flakes, joining them and sticking them to the metal surface. Source employs powder coating on a wide range of items, from furniture and autos to farm and factory equipment and even athletic goods. When we talk about “liquid coating,” we often mean paint or coating that may be applied in a number of different ways, such as by brush, dip, electrostatic spray, and so on.

Hot Dipping

The technique entails dipping the component into a dissolved solution of tin, lead, zinc, aluminum, or solder to generate a metallic coating on the element’s surface. In hot-dip galvanizing, pieces of steel are submerged in a vat of molten zinc. The guard rails along highways often have this finish applied to their exteriors. Corrosion protection is its principal function, especially in severe environments.

Essential Factors to Consider When Choosing Metal Surface Finishing

Several variables determine the approach you use to achieve the desired Oberflächengüte. In general, the most important thing is to research the following three topics:

Surface Finishing Process

Ø  Production Speed of Surface Machining Methods

Consider the needed speed of delivery. Examine the time necessary to perform the various procedures involved in the mixed metal finishing alternatives.

Ø  Degree of the hardness of a metal

This is especially important when applying techniques from the second category. You will need a more intense or vigorous abrasive when you access a harder metal. On the other hand, pressing too hard with softer materials may create damage to the parts that are difficult or impossible to fix.

Ø  Costs and financial projections

There are undoubtedly several processes that, when applied to your specific scenario, seem to be the best option. However, some more challenging jobs may require specialized tools and equipment, causing you to exceed your budget. Check to see whether your decision will save you money in the long term.

Schlussfolgerung

It would help if you now had a better understanding of Oberflächenveredelung due to reading this article. Additionally, you should now be familiar with the numerous finishing choices available for CNC machined components. The product’s finish has a significant role in determining its longevity and its different functions. As a result, ensuring that the appropriate Oberflächengüte is applied is essential.

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Bead Blasting Process: A Complete Introduction For Rookies https://prototool.com/de/bead-blasting/ Thu, 30 Jun 2022 07:34:54 +0000 https://prototool.com/?p=5733 Bead Blasting Process: A Complete Introduction For Rookies
Prototool

Bead blasting is one of the many surface finishes available for a wide array of manufactured parts. It is widely used to deliver a smooth, clean, and shiny appearance on the surface of plastic or metal parts. It can be used across injection molded parts, 3D-printed parts, CNC-machined parts, and more. Today, we explore the […]

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Bead Blasting Process: A Complete Introduction For Rookies
Prototool

Bead blasting is one of the many surface finishes available for a wide array of manufactured parts. It is widely used to deliver a smooth, clean, and shiny appearance on the surface of plastic or metal parts. It can be used across Spritzgussteile, 3D-printed parts, CNC-machined parts, and more. Today, we explore the process itself, its advantages and disadvantages, and why it is one most popular surface finishing techniques.

Bead Blasting Machine

What is Bead Blasting?

Bead Blasting is a surface finish technique that is used to improve the cosmetic appearance of a variety of objects. It is carried out by projecting fine glass beads against the surface of a material to achieve a smooth, uniform finish on the material.

How is Bead Blasting done?

It is a type of shot blasting done with abrasive media. It utilizes high pressure, and an abrasive media (often fine glass beads) shot from the bead blaster gun aimed at the surface of the material to leave a smooth, shiny finish on a part or component. Bead blasting can be used for finishing materials like plastic, glass, metalsund Gummi. The process is usually completed in a bead blasting cabinet. The glass beads used are lime-free, soda-limed, and spherical. They are environmentally friendly and may be recycled for several rounds.

What are the Advantages Of Bead Blasting?

There are many advantages to a choice of surface finish. Some of these advantages include the soft, smooth, and even nature of its finishes. Bead blasting can also improve certain functional properties like mechanical strength, aesthetics, and fatigue performance. Some of the many advantages of bead blasting include the following:

  • Diverse material compatibility
  • Environmentally-friendly process
  • Highly recyclable
  • It is very safe compared to other abrasive blasting processes
  • Achieves uniform surface finish
  • Enhances durability and strength of materials

Industries

The versatility of bead blasting makes it compatible with a wide array of industries. Some of the industries that utilize this finishing technique include:

  • Luft- und Raumfahrt
  • Automobilindustrie
  • Firearms and Military
  • Medical Components
  • Food Processing Materials

Disadvantages Of Bead Blasting

While the advantages largely outweigh its cons, the process still has some disadvantages. Here are some downsides to the process:

  • This kind of finish may not last as long as other abrasive media like steel
  • It is largely used for soft to medium materials as it may take a longer cycle time to apply to tougher materials
Elevating Industries Through Precision in CNC-Bearbeitung und Spritzguss

Applications of Bead Blasting

Bead Blasting can be used for many purposes related to Oberflächenveredelung. They include but aren’t limited to:

  • Peening
  • Cosmetic finishes
  • Deburring
  • Polishing
  • Material preparation for painting
  • Paint removal

The size of the bead materials can also determine the type of application for the process. For instance, smaller beads may be used to perform finishing works that require light finishes, while medium and larger beads find their usage around cosmetic finishing, deburring, and cleaning rough surfaces on parts.  

Prototool Manufacturing in China

Prototool is one of China’s leading manufacturing hubs for Additive manufacturing, CNC machine services, and Injection Molding. We offer kinds of supporting surface finish processes, such as bead blasting, to deliver the perfect combination of aesthetics and functionality to your CNC-finished and injection-molded products. Klicken Sie hier to get in touch with us and receive a free quote and project review.

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