How should i manufacture a car badge? 1

[drivefast]

My boss would like me to create an intricate badge that will be placed on a line of cars he is introducing. The badge is a a national flag that contains the cars name beside it. We will only be making 100 or so and I don't know if it will be cost effective to mold them out of plastic. I considered making it out of two peaces of aluminum. The top peace could have the letters and colored parts of the flag lasered thru and the bottom peace would be painted to act as a contrasting backstop. Do you have any other suggestions on how I can have this made cheaply?

 

[MintJulep]

For that volume, lost-wax casting probably makes sense.

Make one as you propose, or with sink-EDM and use that to make some rubber molds which in-turn get used to make wax cores.

Or just have 100 cores "printed" via stereo-lithography and use them directly as cores.

 

[rb1957]

btw, it's "piece", as in "piece of pie" not "peace" as in "war and peace"

 

[IRstuff]

Maybe you should talk to someone who manufactures lapel pins and buttons?

TTFN

FAQ731-376

 

[KiwiMace]

Spin casting directly into a rubber mould is the way forward in the lapel pin business. They hand paint the colouring.

 

[drawoh]

drivefast,

Contact someone who makes sports trophies. I have seen some metal badges with logos of the ski club I belong to. They look good. I do not know how they did it.

JHG

 

[KENAT]

Does it need to be coloured?

Some kind of laser etching might work.

Or either drawoh or IRstuff suggestions aren't bad.

KENAT, probably the least qualified checker you'll ever meet...

 

[MikeHalloran]

For that lot size, I might consider using a CNC mill to hog the parts out of aluminum plate and cut all the recessed detail, then color anodize the parts, then sand/buff the top to bare white metal, and seal with lacquer.

Talk to a color anodizer before taking my advice; they bring some amazing stuff to trade shows.





Mike Halloran
Pembroke Pines, FL, USA

 

[CoryPad]

I think Mike's advice is best.

Regards,

Cory

Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.

 

[MikeHalloran]

<blush>


Mike Halloran
Pembroke Pines, FL, USA

 

[KENAT]

We put our company logo on little cassettes that measurement tips for our tools go in. I think they're aluminium and they use laser etch. You end up with similar effect to what Mike's proposing.

KENAT, probably the least qualified checker you'll ever meet...

 

[gearguru]

Being a geocacher I would look for a manufacturer of "geocoins". They are purchased by individuals and very often made on request in small amunts. On EBay you can see how they look like; type "geocoin" in google for some links.

 

[strokersix]

If you want to try injection molded plastic, contact protomold.com. You provide the CAD model and they do it quickly and relatively low cost. Probably less than whittling them all from solid.

I'm not affiliated with Protomold but have used their service.

 

[pierdesign]

electroform: very nice, super sharp detail created in basically heavy plated solid copper or nickel. Affordable as they're hollow backed. Printed and/or painted after.

Dome it: most label, decal or membrane switch manufacturers make these sort of vanity labels. Basically a printed substrate, your graphics, then a dome of clear elastomer is poured on top. Numerous vehicles, like the Neon, use this method.