Recommendation required for Plastic process 1

[bearmatt]

Sorry to bother the experts here, but having trouble getting some direction.
Is there another process beside hand casting that might suit the following. I hv ctcd a couple of fabrication firms that advised tooling would be too expensive.
We require apprx 1000 hard plastic tiles, approx 400x400x5mm with a patterned face. There needs to be approx 20 patterns.

Thank you

 

[patprimmer]

50 by each pattern is a casting job.

As already discovered tooling will beat you for injection moulding.

One possibility is a bolster that is 400 by 400 and has removable inserts cast from a filled epoxy like Devcon for the pattern, but I strongly suspect it will still be to expensive.

Regards
Pat
See FAQ731-376 for tips on use of eng-tips by professional engineers &

http://eng-tips.com/market.cfm

for site rules

 

[MikeHalloran]

You could sawcut or maybe shear the tiles from sheet, then heat-emboss the pattern into one face.

The tooling could be as simple as some flycut aluminum plates, on which you would rest the pattern master, then the tile blank, and then run the stacks through cycles in an annealing oven (which is actually a significant expense if you don't already have one), and let the plastic sag down over the pattern.



Mike Halloran
Pembroke Pines, FL, USA

 

[Pud]

You could investigate laser engraving (ablation)

e.g.

http://www.tapplastics.com/info/laser_engrave.php

There are probably thousands of sign makers who can do this.

Cheers

Harry

http://www.tynevalleyplastics.co.uk

 

[MacGyverS2000]

If you decide lasering is an option, and you're semi-local, I may be able to help you with that. 50 tiles per pattern is definitely a non-repeating manufacturing process, and laser is one method that often fits that description.

Dan - Owner

http://www.Hi-TecDesigns.com

 

[bearmatt]

Thank you all,

I thought laser etching 1000 might be a bit slow and expensive, but will definitely look into it further.
In Australia, so sorry Dan.

Mike, I like the idea of heat-emboss, albeit the annealing ovens aren't cheap as u mentioned. These tiles will have a hard life, and may only last a few months, so it might be worth the investment.

 

[patprimmer]

Aus is a good place for short runs.

Try C&C plastics at Rydalmere in Sydney if that suits. I know others in other states if Sydney does not suit.

Regards
Pat
See FAQ731-376 for tips on use of eng-tips by professional engineers &

http://eng-tips.com/market.cfm

for site rules

 

[bearmatt]

thanks Pat

 

[MacGyverS2000]

If you determine lasering is a real possibility, I can suggest some fellow Aussie laserers.

Dan - Owner

http://www.Hi-TecDesigns.com

 

[raynjer]

Have you considered a plastic injection mold with interchangeable inserts made of aluminum?
Cost wise it won't too prohibitive compared to other ideas floated. Your cost is going to be fairly high regardless which way you go as you have 20 different patterns.
If there is any chance that you will need more than a 1000 pieces - a mold may work out better.