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The Reliable Standard Operating Procedures
We, at Foison Metal, pride ourselves in being one of the most efficient surface treatment tech and complete manufacturers.
Leading the signs and metalcraft industry in China, our company has several features as feathers in our cap. These include processing workshop, CNC workshop, polishing workshop, and backing workshop. Further, it offers stamping workshop, electroplating workshop, sandblasting workshop, and QC lines. The facilities we offer include die-casting, silkscreen, and imported mould room equipment.
Moreover, it comprises batching, drawing, machining, CNC, polishing, and pad printing workshops. You can expect quick delivery, raised efficiency, and full-on supporting quality from us at all times.
Screen Printing
Screen printing uses a mesh screen, ink, and a squeegee to move a stenciled design onto a horizontal plane. You can use it on metals with the specified inks. The simple technique involves making a stencil on a fine mesh board. Later, it is pressed through the ink (or paint, with illustration and posters) for making an impression on the surface below as per the design.
One of the main reasons to apply screen printing is to produce distinctive colors. That is to say, it even offers dark textures! Likewise, the ink or paint lies in layers outside the texture, which gives the print a pleasing material quality.
Based on your choice, you can select PANTONE or six spot colors that will help you bring the desired results on metal labels or metal coasters. Screen Printing will make the metal more opaque, combining it with textures, colors and gloss will bring a unique decoration with a much-finished look.
One of the significant advantages of screen printing is that it’s a truly viable answer for mass printing as it’s incredibly cost-effective.
Other benefits include:
- A greater outcome than computerized prints
- More durable for prints that require usage over longer period
- Wide range of print materials such as stainless steel or bare metals.
- Used on any type of metal, flexible or soft, durable or hard.
We bring the best standard production process and QC for everyone who collaborates with us. We conduct a professional product pre-assessment analysis and mould flow plan. Besides, our engineers do constant project follow-ups for better engagement.
Our production process follows stringent SIP/SOP implementation of production. Thus, a timely inspection of the entire production process and comprehensive quality supervision makes us stay updated with all the new processes.
Electroplating
Electroplating is the method of applying a metal coating over other metal (or other conductive surfaces) through the process of electro-deposition. The deposited metal turns out to be a part of the current item which is used with the plating via electroplating.
The electroplating process involves immersing both an anode and a cathode (the metal part to be coated) in an electrolyte solution. The solution comprises salts, including the metal, to be plated. DC or Direct Current is passed through the solution, as the metal ions transfer on the cathodic surface, resulting in the coating of metal onto the item.
Generally, the application of the electroplating process improves the aesthetic appearance of the base material. Various industries use this method on a day-to-day basis. This is because it helps in building thickness via the constructive use of layers of the substrate.
Additionally, it protects the primary material from any damage because of some unavoidable environmental factors. As a result, it helps to maintain product longevity, making the product resistant to corrosion and abrasion.
Some significant benefits of electroplating are:
- Electroplating works as a deterrent on the substrate, ensuring protection against natural conditions. This boundary can secure the metal against corrosion brought about by the climate.
- Exterior materials are frequently plated with slender layers of valuable metals to make them more radiant and improve appearance.
- Copper and silver plating improve the electrical conductivity, offering a financially savvy, and an effective alternative for the same in gadgets and electrical segments.
Die Casting
A metal casting method, Die casting is identified by pressing molten metal with high pressure into a cavity. Two hardened tool steel dies are machined into a shape. In other words, they act similar to an injection mold to build the mold cavity.
Many die castings, specifically pewter, zinc, aluminum, copper, lead, magnesium, and tin-based alloys, are made from non-ferrous metals. A hot- or cold-chamber system is used according to the type of metal being cast.
Die casting is mostly required for massive similar-like creation. For instance, when you need to cast numerous components of a similar kind. Whether you use high pressure during the assembling cycle, you get a high projecting quality.
You can mostly use Die Casting for creating extremely slim (up to 1 mm) and lightweight segments. Most ordinarily, the manufacturing of Die Casting components happens in the automotive industry. A few of the examples include manifold, wheels, cylinder heads, etc.
- The components are robust, dimensionally steady.
- It can give complex shapes within the given dimensions as compared to the other production techniques.
- High paces of production with next to zero machinings.
- The components produced with die casting are with more slender dividers than those possible by other projecting techniques.
- These are a lot stronger than elective plastic infusion moldings.
- Large-scale manufacturing allows many indistinguishable castings inside the mentioned dimensions.
- The cast includes outer threads on components.
- Zinc castings offer incredible erosion opposition.
CNC Cutting
CNC, the abbreviation for Computer Numerical Control gadgets, uses specific instruments to rapidly and productively make items. With CNC cutting, a specialist makes a design dependent on what the client needs using a product program like CorelDRAW or AutoCAD. After finalizing the drawing, you put a part of the metal or the needed material on the cutting surface. You usually use this process to create advanced products and shapes.
The computer enforces a sign onto the CNC machine, which thus deciphers the design. With a model that meets all prerequisites, the administrator can handle unique items. For this machine to cut, the instrument moves back and forth and left and right along the axes while following the state of the design. It offers perfect precision, giving away many finishing options.
CNC Cutting helps cut machined parts, as it is the best and the most effective system. A few of the most common materials that can use CNC for cutting are aluminum, steel, and composites.
CNC cutting is a strong process that can help cut the metals in sheets or as flat plates. Moreover, you can have square or round tubing. With CNC, you have options such as waterjet, plasma or laser. Nevertheless, it depends upon the style and type of metal that you wish to cut. We tend to use an ultra-high precision technical knife with smooth and clean edges. It not only allows us to make customized shapes but also lets us punch holes, and dig grooves on the surface of the metal.
- The precision of the CNC machine guarantees predictable item quality. The cycle is more accurate than manual machining and can be rehashed in the very same way again and again.
- As with computers’ help, you can easily control the machines, thereby increasing the production speed and efficiency.
Sandlasting
Sandblasting, also known as abrasive blasting, involves finishing the surface with the help of a powered machine. Generally, you make use of an air compressor in the sandblasting machine for spraying abrasive fragments under high pressure. They adopt sand particles during this process as they make the metal surface smoother offering a good texture after making the necessary hits with adequate pressure.
Sandblasting uses the grating properties of sand to make smoother surfaces with fewer actual defects and deformities. It is a well-known fact that sand is quite abrasive. For instance, sandpaper contains many granular particles of sand. When scoured against a surface, the sand eliminates a portion of the top-layer, making it smoother than its current coat. Sandblasting works in the same way.
The only difference stands with it using highly pressurized sand in a chamber that blasts around 50 to 130 pounds of sand PSI (per square inch). It intervenes a frosting process where high pressure gas drives steel ball sand or glass sand to make a difference to the surface of the metal with the help of a rotary spray gun. The process makes the metal surface ready to paint. Moreover, it can refurbish the metal to provide a completely different layer.
- Effectively remove mill scale, dirt, oil, and rust on the surface of the steel components
- Speeds up the whole metal cleaning process
Etching
Etching is a profoundly accurate process used at different stages of manufacturing for delivering high accuracy metal parts. It is a high exactness subtractive assembling measure in which you use temperature controlled etching synthetics or chemicals for eliminating certain materials. This leads to creating high accuracy metal parts in any ideal shape.
You can use the different forms of metal etching. Acid-based etching stands as the most common of all. In this process, you cover the entire metal area with waxy ground, exposing just the etched surface. This cover protects the metal from etching while the acid-exposed traces the necessary design
Etching helps to uncover the microstructure of the metal through a specific enforcement of chemicals. Likewise, it eliminates the slim, profoundly disfigured layer exposed during grinding and cleaning.
You can try chemical etching if you need to make complex, multi-layer, high-exactness metal parts, similar to what we do on metal cards. When chemically etched, you can see the part embossed inside. It is one of the main processes to offer a clean surface on metal.
- The etching is a low-cost yet an effective method.
- Stamped, laser, and waterjet cut parts inclined to bend, etched parts offer smoother surfaces with zero material debasement.
- You can chemically etch any sheet of metal that is between 0.01 mm and 1.5 mm thick.
- It offers exact uniform parts.
- It shows fine details of complicated designs with sharper edges
- You can control micro accuracy cycles for multidimensional etching.
Laser Engraving
Laser engraving simply means engraving the metal surface to change its appearance with a laser beam. Compared to other more customary techniques, the heat of the laser beam dissolves and disintegrates the part of the focused material. At the end, you get a permanent and a smooth engraved finish on the metal.
This technique is fast, as it peels out the exposed surface with each pulse of the laser. The profundity of the imprints depends on the number and the amount of time the laser beam surfaces the material.
Laser Engraving helps in making the necessary marks on the surface of a material. It is mostly used on ferrous metal cards. Besides, it is more viable than the traditional etching processes. For example, you can make use of laser engraving procedure to make subtle changes in the designs of jewelry or beautiful engraved names on metal nameplates.
Moreover, you can use it for compelling artwork or clinical gadgets. It gives an aesthetic appearance quickly by simply melting the surface it comes in contact with by enforcing a high amount of energy onto a small area. More or less, it depends upon the depth of the surface oxide layer to burn, baring the passive aluminium.
- Laser Engraving fits to work with a wide range of materials.
- Laser engraving is an inconceivably efficient process. It can undoubtedly switch among materials and scope of profundities, offering its users numerous outcomes.
- There is no abrasion damage as it does not come in contact with the metal.
- It can work at any depths.
- The portion exposed simply vaporises. So, you find no other pieces of the metal left on the surface.
Anodizing
Anodising refers to the electrolytic process for creating thick oxide coatings on aluminum and its different forms. The oxide layer usually is 5 to 30 µm in thickness and gives improved surface protection from wear and tear or erosion. Anodic oxide structure is made from aluminum substrate and is filled with aluminum oxide.
However, you do not apply aluminum oxide as you plate or paint. In fact, it completely infuses with the integrated aluminum substrate, so you keep it free from stripping or chipping. It has an exceptionally ordered, permeable construction that also allows sealing or coloring.
Anodizing most commonly aims for improving avoiding erosion on specific kinds of aluminum composites. Aluminum combinations that are under water constantly make best use of the process of anodizing. For instance, you can find anodizing as a stage in the procedure while making ship bodies, dock segments, and oil rig structures.
Anodizing additionally helps in abrasion control. Aluminum that has not been oxidized is a moderately delicate material as compared to steel or titanium. We usually refer to anodizing to oxidizing the metal sheet surface. This process best offers precision and efficiency to creating a range of perfect metal cards.
- Amazingly long-life expectancy and offer huge monetary preferences with timely maintenance
- Creates a wear-resistant and a hard layer to protect the aluminum
- More resistant to corrosion
- Offers better lubrication
- Used as a dyeing material to color the aluminium
The presence of advanced equipment ensures the precision of castings. We chalk out each of the levels of processes diligently. Plus, we carefully select all the material for die-casting during the process of production.
In addition, we provide special attention to make sure there is less batching, stability in quality, polishing, and fine grinding. Nevertheless, in our production, you will only find stable dimensions and precise edges. That is to say, you will find no dead corners at all.
The primary production processing includes mould improvement, surface colouring, mould making, and surface painting. Foison Metal provides you with the best product experience. Even the alloys that are rare in the industry are procured by us, including copper, zinc, aluminium, stainless steel, and aluminium-magnesium.
