Secondary Manufacturing Processes
Secondary manufacturing processes are all the services that happen after the initial forming of the plastic part. These services are used to improve the aesthetics, functionality, and precision of the molded plastic parts. Secondary manufacturing processes allow manufacturers to deliver a more complete, value-added product to the customer, meeting their specific requirements beyond just the initial molded part.
Types of Secondary Manufacturing Processes
Some methods used for secondary manufacturing processes include:
Epoxying or Light Curing
Epoxying is the process of using epoxy resin, a type of thermosetting polymer, used in various applications such as bonding, coating, and encapsulating materials. Epoxy resins have excellent adhesion, strength and versatility. Light curing is a specific curing method used for certain types of resins that remain inactive until exposed to ultraviolet light, which causes the resin to harden.
Insert or Heat Staking
Heat staking involves inserting a metal or plastic insert into a molded hole, then heating the insert, causing the surrounding plastic to melt and flow around it, creating a secure and permanent bond. This process is an efficient method that provides a strong and reliable bond.
Ultrasonic Welding
Ultrasonic welding is used to join two pieces of thermoplastics together, without the use of adhesives or fasteners, using high-frequency ultrasonic vibrations. This process creates a strong bond and is widely used in plastics manufacturing for its speed, precision, and the strength of the resulting welds.
Pad Printing
The pad printing process involves transferring a 2D image onto a 3D object using a silicone pad. This method is used for printing on irregularly shaped surfaces, carved surfaces, or surfaces with varying textures. Pad printing is used for branding, identification, instructions, or decorative elements to products.
Laser Etching
Laser etching is the process of using a laser beam to create a permanent mark or design on the surface of a material. This technique is highly precise, allowing for detailed patterns, logos, text, or images to be engraved onto materials.
Standardized Production Part Approval Processes
The Standardized Production Part Approval Process (PPAP) is a standardized method used to ensure that suppliers and manufacturers have met all the necessary requirements for the production of parts or components.
There are many secondary manufacturing processes within plastics manufacturing. Some other secondary services include hydrographic imaging, hard form in-mold labeling, milling, and drilling.