Production technologies

For each of our product ranges, we use a different mixture of state-of-the-art technologies, along with expert proffesionals on each field, to ensure perfect consistency during the creation of top quality and accurate products, no matter the complication of the desing to be recreated. Among all of our production technologies used in the manufacturing of each of our products, you can find expert usage of some of the following:

3D Printing

3D printing, also known as additive manufacturing, is a process of creating three-dimensional objects by layering or adding material in a sequential manner. It is a revolutionary technology that has gained significant popularity and has various applications across different industries.

The process of 3D printing typically involves the following steps:

  • Designing: The first step is to create a digital 3D model of the object using computer-aided design (CAD) software. The design can also be obtained from 3D scanning, where an existing object is scanned to create a digital model.
  • Slicing: The digital 3D model is then sliced into multiple layers or cross-sections using slicing software. Each layer is a thin horizontal section of the object, which will be printed individually.
  • Preparation: Once the model is sliced, the 3D printer needs to be prepared. This includes selecting the appropriate printing material, such as plastics, metals, ceramics, or even composite materials. The printer's build plate or bed is usually prepared with a special surface or adhesive to ensure proper adhesion of the printed object.
  • Printing: The 3D printer starts building the object layer by layer. It does this by depositing or solidifying the chosen material according to the sliced digital model.
  • Post-processing: Once the printing is complete, the object may require some post-processing steps. This can include removing support structures used during printing, cleaning or curing the printed object, and applying finishing touches like sanding or painting.

3D printing offers several advantages:

  • Design Freedom: 3D printing enables the creation of complex geometries and intricate designs that may be challenging or impossible to achieve using traditional manufacturing methods.
  • Rapid Prototyping: It allows for quick and cost-effective production of prototypes, enabling iterative design improvements and faster product development cycles.
  • Customization and Personalization: 3D printing facilitates the production of unique, customized objects tailored to specific individual needs or preferences.
  • Manufacturing on Demand: With 3D printing, objects can be manufactured on demand, reducing the need for large-scale inventory and enabling decentralized production.

Resin casting

Resin casting is a manufacturing process that involves the pouring of liquid resin into a mold to create solid objects. It is a versatile and widely used method for producing prototypes, models, decorative items, and various other products.

The resin used in casting is typically a two-part liquid material that undergoes a chemical reaction, usually called curing, to solidify and form a durable and rigid object. The two parts of the resin are usually referred to as the resin and the hardener. When mixed together in the correct proportions, they initiate a chemical reaction, causing the liquid mixture to harden and solidify over time.

The process of resin casting typically involves the following steps:

  • Mold Preparation: A mold is created or selected to define the shape and form of the object to be cast. Molds can be made from various materials such as silicone, rubber, or metal, depending on the desired level of detail and complexity.
  • Mixing the Resin: The liquid resin and hardener are carefully measured and mixed together according to the manufacturer's instructions. Thorough mixing ensures proper curing and the desired material properties.
  • Pouring the Resin: The mixed resin is poured into the mold, which is usually placed on a level surface or inside a containment box to prevent leaks. The resin fills the mold and flows into all the intricate details of the mold cavity.
  • Curing: The resin is left undisturbed for a specific period to allow it to undergo the curing process. The curing time can vary depending on the type of resin used and the size and thickness of the cast object. During curing, the resin gradually hardens and solidifies, taking on the shape of the mold.
  • Demolding: Once the resin has completely cured and hardened, the mold is carefully opened or separated to release the cast object. Demolding should be done with caution to avoid damaging the object or the mold.
  • Finishing: After demolding, the cast object may require additional finishing touches such as trimming excess resin, sanding rough edges, or polishing the surface to achieve the desired final appearance.

Resin casting offers several advantages:

  • Detail and Replication: Resin casting can accurately replicate intricate details and textures, capturing the fine features of the mold.
  • Material Options: Different types of resin materials are available, offering a range of properties, including transparency, color options, flexibility, and hardness.
  • Versatility: Resin casting can be used to produce a wide variety of objects, from the finest details to larger-scale parts.

Computer-controlled cutting

Computer-controlled cutting, also known as vinyl cutting or contour cutting, refers to a process in which a plotter machine with a sharp blade is used to precisely cut various materials, such as paper, cardstock, vinyl, fabric, and thin plastics. The plotter is guided by computer software, which controls its movements to create intricate and accurate cuts.

The Computer-controlled cutting process typically involves the following steps:

  • Designing: The first step is to create or import a design into graphic design software. The design can be a shape, a pattern, or even complex artwork. The software allows for precise control over the dimensions, position, and cutting path of the design.
  • Material Preparation: The material to be cut is prepared and loaded onto the plotter machine.
  • Setting Parameters: The cutting parameters such as blade depth, cutting speed, and cutting pressure are adjusted based on the material being cut. Different materials require different settings to achieve optimal results.
  • Alignment and Calibration: The plotter needs to be properly aligned with the design and the material to ensure accurate cutting. This can involve calibrating the plotter to account for any mechanical variations and ensuring the cutting area corresponds correctly with the design.
  • Cutting: Once the setup is complete, the plotter moves along the designated cutting path, guided by the instructions from the design software. The sharp blade mounted on the plotter precisely cuts the material according to the desired design. The blade cuts through the top layer of the material while leaving the backing intact.

Computer-controlled cutting offers several advantages:

  • Precision: Plotter cutting machines are capable of highly accurate and intricate cuts, ensuring precise replication of the design.
  • Versatility: Plotter cutting can be used with various materials, allowing for a wide range of applications across different industries
  • Customization: Plotter cutting allows for the creation of customized designs, patterns, or lettering, offering flexibility and personalization in the final product.
  • Efficiency: Plotter cutting machines can perform cuts quickly and consistently, increasing productivity and reducing production time compared to manual cutting methods.

Process printing

Process printing, also known as four-color printing or CMYK printing, is a widely used method for reproducing full-color images and designs in print. It involves the combination of four ink colorsócyan (C), magenta (M), yellow (Y), and black (K)óto create a wide range of colors and shades, as well as additional inks for enhancing color accuracy, and white (for transparent decals) and clearcoat inks for decal printing and contouring.

The process printing method is based on the subtractive color model, where colors are created by subtracting wavelengths of light from white. In this model, cyan, magenta, and yellow are the primary colors, and black is added as a separate key color (K) to improve contrast and provide richer blacks.

The process printing workflow typically involves the following steps:

  • Design Preparation: The original design or artwork is prepared digitally using graphic design software. The design may consist of photographs, illustrations, or a combination of both. It is important to ensure that the design is set up in the appropriate color mode (CMYK) to accurately represent the final printed colors.
  • Color Separation: In the color separation stage, the original design is separated into four separate color channelsócyan, magenta, yellow, and blackóusing specialized software or prepress tools. Each color channel represents the amount of ink that will be applied to the paper for that specific color. Additiional base colors can also be used to enhance the reproduction of specific tones, such as reds and greens, and special colors such as whites and varnish
  • Plate Creation: Once the color separation is complete, individual printing plates are created for each color channel. These plates act as stencils that transfer the corresponding ink color onto the printing surface. Each plate carries a halftone pattern of dots, varying in size and density, to represent the different tones and shades of the specific color.
  • Printing: The printing device is set up with the printing plates, and the printing process begins. As the paper moves through the device, each color plate transfers its respective ink color onto the paper in a precise registration, layering the colors to create the final composite image.
  • Color Control: During the printing process, color control measures are taken to ensure accurate color reproduction. This can involve periodic checks and adjustments to maintain consistent color balance and density across the printed sheets. Color proofs and color management techniques are often employed to guide the press operator in achieving the desired color accuracy.

Process printing offers several advantages:

  • Full-color Reproduction: Process printing allows for the reproduction of a wide range of colors, including subtle gradients and shades, providing a visually appealing and vibrant output.
  • Versatility: Process printing can be applied to various print media, including brochures, magazines, catalogs, packaging, and more, allowing for a wide range of applications.
  • Consistency: Once the color separation and plate creation are properly set up, process printing ensures consistent color reproduction throughout the print run, maintaining visual continuity.

Vacuum forming

Vacuum forming is a manufacturing process that involves shaping a sheet of thermoplastic material by applying heat and pressure while using a vacuum to draw the material against a mold or form. It is commonly used to create three-dimensional objects with a hollow or concave shape.

The vacuum forming process typically involves the following steps:

  • Mold Preparation: A mold or form is created, typically made of wood, aluminum, or even composite materials by 3D printing processes to create the most accurate parts. The mold defines the desired shape and surface details of the final product. It can be a positive mold (replicating the desired shape) or a negative mold (creating a mold cavity).
  • Material Heating: A sheet of thermoplastic material, such as ABS (Acrylonitrile Butadiene Styrene), PVC (Polyvinyl Chloride), or polystyrene, is clamped into a frame or holder. The material is heated until it becomes soft and pliable, but not melted. This can be done using a heating element, infrared heaters, or ovens.
  • Forming: Once the material reaches the desired temperature, it is moved over the mold and carefully lowered or drawn down onto the mold surface. A vacuum is applied to the space between the material and the mold, which pulls the material tightly against the mold, conforming to its shape.
  • Cooling and Solidification: Once the material is in contact with the mold, it is cooled to a temperature where it solidifies and maintains its shape. This can be achieved by blowing cool air or spraying water onto the material or using a cooling station. The cooling process may also involve the use of a release agent or mold release to facilitate the removal of the formed object from the mold.
  • Trimming and Finishing: After the formed object has cooled and solidified, it is removed from the mold. Any excess material or flashing is trimmed off using computer assisted trimming machines to ensure a perfect fit on your scale model. Additional finishing touches such as sanding or polishing may be applied to achieve the desired final appearance.

Vacuum forming offers several advantages:

  • Versatility: Vacuum forming can be used to produce objects of various sizes, shapes, and complexities. It is suitable for both simple and intricate designs, including prototypes, packaging, protective covers, trays, and more.
  • Fast Production: The vacuum forming process allows for relatively quick production cycles, as it involves heating and forming a single sheet of material at a time. This makes it suitable for rapid prototyping and short lead-time production runs.
  • Material Options: Vacuum forming can be performed with a wide range of thermoplastic materials, providing flexibility in material selection based on factors such as strength, transparency, color, and cost.

Photo Etching

Photoetching, also known as chemical etching or photochemical machining, is a precise manufacturing process used to create intricate patterns, designs, or features on thin metal sheets through the use of chemical etchants and photoresist materials.

The photoetching process typically involves the following steps:

  • Design Preparation: The desired design or pattern is created using computer-aided design (CAD) software or other graphic design tools. The design is converted into a digital file, which will serve as the blueprint for the etching process.
  • Photoresist Application: A thin layer of photosensitive material, called photoresist, is applied onto the metal sheet. This can be done through methods such as spraying, rolling, or laminating. The photoresist serves as a protective layer that will undergo a chemical reaction when exposed to light.
  • Exposing the Photoresist: The metal sheet with the applied photoresist is then exposed to UV light or another suitable light source through a photomask. The photomask contains the negative image of the desired design. The light-sensitive photoresist material undergoes a chemical reaction and hardens in the exposed areas, while remaining soft in the unexposed areas.
  • Developing: After exposure, the metal sheet is processed in a developing solution, which removes the unexposed or soft photoresist, leaving behind the hardened resist in the desired pattern or design. This step reveals the metal surface in areas where the etching will take place.
  • Etching: The metal sheet with the patterned photoresist is immersed in an etchant solution, typically an acid or chemical mixture, which selectively removes the exposed metal areas. The etchant dissolves the unprotected metal, creating recessed or raised features based on the desired design. The etching process continues until the desired depth or level of detail is achieved.
  • Stripping and Cleaning: After the desired etching is completed, the remaining photoresist is removed using a stripping solution or solvent. This step exposes the final etched metal features and prepares the sheet for any additional treatments or finishing processes.
  • Finishing: The etched metal sheet may undergo additional processes such as deburring, polishing, plating, or coating to achieve the desired appearance and functional properties.

Photoetching offers several advantages:

  • High Precision: Photoetching enables the production of highly precise and intricate designs with tight tolerances, including fine details, sharp edges, and complex patterns.
  • Versatility: Photoetching can be applied to various metals, including stainless steel, brass, copper, aluminum, and alloys. It is suitable for creating a wide range of products such as electrical components, jewelry, nameplates, filters, shims, and more.
  • Reproducibility: Once the photoresist and etching parameters are properly set up, photoetching allows for consistent replication of designs across multiple sheets or batches.