Reflectors are everywhere

Whatever form of transport you take, from car to bicycle, reflectors play a significant part in your safety.
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Metallizing is a precision process

Metallizing is a precision process where coatings are measured in microns. The manufacturing process has to be sophisticated
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Application and importance of Nylon moulding

The durability of any product in the market of plastic determines its price and the demand. If the product is easily handled and flexible in usage, then the manufacturers make it. The rule of demand and supply is simple and it is applicable to everything in the market. Same is the case with the nylon. Nylon is popular in the market and in the plastic industry because of the certain properties that it possesses. The performance of the nylon products is very satisfactory and people use this material in various ways.

Basically nylon is a material that is a thermoplastic and it is silky in texture. It was first introduced in the year 1938 when first commercial usage of nylon came into the market. A nylon toothbrush was introduced and after that it was used in a variety of the products like women stockings. Nylon is not a natural product and in reality it is a polyamide. It was the most successful experiment of the synthetic polymers. After the introduction of the nylon in the market, it was used in place of the silk and the industry faced a huge change. Parachutes, ropes, clothes, vests, tires and many other military related products were made out of the nylon moulding after the time of World War 2.

The moulding compounds are very popular in the market nowadays and other than nylon, other polyamides and synthetic polymers are also used for various purposes. Metal parts of the machinery that are used in the tool industry and the vehicles industry are made from the nylon. Hence in every industry the nylon moulding products are used. There are many benefits of this polyamide and because of the amazing qualities of this material it is being used for decades.

Nylon moulding products are famous for their non-corrosive properties. They can resist saline environments as well as dry and wet atmosphere very well. Some years ago the aluminium products were very popular and even nowadays they are very much in demand. However nylon moulding is replacing every other material that was used before. Nylon is a tough material and it has a high resistance to every unpleasant environment.

Once you invest in nylon, it gives you long time benefits.

Another thing you must know about the nylon moulding products is the insulation of the electric field. The electrical industry uses the nylon as a basic material in all of its products whether there are insulators, switches, or cables. You must have heard about the power tool housings. These are the practical applications of the moulding products made from nylon.

Many applications of the nylon moulding products are seen in the market. First of all you can have a look at the footwear industry. Almost all of the shoes and other footwear are produced by moulding nylon. Nylon has a high share in the manufacturing of the consumer goods. You can find nylon products everywhere in your home whether it is in the form of a comb, a toothbrush or a cup.

Hence in electronics, medical industry, military and automotive, you can see the abundance of the products that are made up of nylon.

Please visit our website for more information on nylon moulding and plastic injection moulding.

Plastic Injection Moulding - A Detailed Overview

The history of injection moulding dates back to around 19th century. Ever since the invention of the injection, moulding machines have undergone several modifications to attain the form widely used today. Initially, the injection moulding methods were based on the die casting technology where immense pressure was applied to obtain the desired shapes. The plastic injection manufacturing became widely popular after the Reciprocating Screw moulding machine acquired the patent rights in 1956.

Raw Materials

There are several kinds of raw materials used for the manufacturing of the plastic injections. However, the thermosetting plastic, elastomers and thermoplastic polymers (resins) are widely used in the production process due the presence of greater viscosity in these materials.

Equipment

The Plastic injection moulding machines have basic component parts such as material hopper, heating unit, plunger etc. These machine parts are used to build pressure and keep the moulds in proper order to give the perfect shape once the molten material is poured inside it. They are also called presses, working in accordance with the tonnage ratings. Tonnage is the capability of the machine to exert clamping force during the manufacturing process to keep the moulds in closed position. The tonnage may range between 5 tons to more than 9000 tons depending upon the rigidity of the raw materials and the projected area of the moulding parts.

Plastic Injection Moulding Process

Melting Polymers: There is a broad and cylindrical melting unit in the injection-moulding machine, where the polymer is converted into liquid under high temperature and pressure. The polymer is filled in an auger, which has an opening at the bottom. The auger is introduced into the melting unit using a hydraulic motor. A valve system at the bottom of the cylinder restricts the passage of the liquid into moulds.

Pouring the Liquid Material into the Moulds

Once the heating process is over, the auger is pushed further to pour the liquid polymer in to the moulds to give the requisite shape to the injections. The moulds are compressed under huge pressure to keep them intact and in proper position. During this process, the liquid is poured twice or more to ensure there are no air spaces left.

Cooling

 After the moulding, the entire mould is introduced to cooling for compact solidification of the plastic injections, which consumes the major time-period during the entire manufacturing process. The cooling is done by passing air or water over the heated moulds or introducing cold water through small holes on the mould surface.

De-moulding

Once the cooling process is over, the compact plastic injections are ready for removal from the moulds. The clamp on the mould is unlocked to open the mould and derive the injection. The entire process is completed and the mould is now ready for the next unit manufacturing.

Plastic injections are affordable compared to other forms of injection. The cost of production mainly depends on the type of machineries. In the long run, this is a lucrative business. The plastic injection moulds are widely used in the manufacture of a number of other plastic products.

Please visit our website for more information on our services pertaining to plastic injection moulding.

Injection Moulding - Guidelines and Advantages

Injection Moulding - What is this?

Injection moulding is one of the most popular ways to create plastic products. For example, you are having a manufacturing company and you need to manufacture a large amount of plastic products in a short time period, also those products should be in same size. Then you could use plastic injection moulding to manufacture your products faster than ever before. The best thing about it is that it is cost effective and this moulding also requires little supervision from staff. Injection moulding machine works in a few stages. In the first stage, the given plastic is melted and then that melted plastic is inserted into a mould machine. That mould machine is then squeezed together to create a shape for your plastic product. The second stage is cooling stage. Here, the moulding machine will cool all your formed plastic products.

Nowadays many people are using this type of moulding to make their product faster and also the injection moulding is more accurate. All the parts in the moulding machine are computerized that means all your work will run like clockwork and the outcome will be more accurate. Handmade plastic products can be a nightmare and sometimes will go wrong. Injection moulding products are always better than our handmade plastic products. Nowadays most of the car manufacturing companies use this injection moulding a lot. For example, the lid of your car's radiator will be manufactured using this technology. There are millions of cars made every year all over the world and therefore this sort of process is required to make sure accuracy and speed.

Some Design Guidelines for plastic injection moulding:

Now we are going to see 5 more design techniques for injection moulding.
1# You should avoid small holes when you are designing a perfect product. Because these small holes are too intricate to mould, these small holes also lead to tool breakage.
2# If you want any hole in your product, through-holes are best.
3# sometimes there will be a variance in surface consistency or angle. This variance is totally depending on the type of material used. Sometimes this variance is little consequence for some products. But if your moulding design requires an exact surface or angle then you should be careful when designing that product.
4# You should use the uniform screw sizes, because they will make your manufactured product much more accessible to many people.
5# Each additional component in your manufactured product will increase the risk of anything going wrong. So always you should make your product more and more simple. Then only it will be easy to handle.

Advantages injection moulding:

1# This injection moulding allows you to create more products within a short time period.
2# When manufacturing your product you may use fillers, these will increase product strength.
3# You can use more than one material.
4# Human work is reduced
5# Design flexibility
6# The outcome will be more accurate than handmade plastic products.

These are some design guidelines and advantages about injection moulding.

Please visit our website for more information on our services pertaining to injection moulding.

Why metallize plastic

Metallized plastic is cheaper, lighter, corrosion resistance and are easier to work than plated metal parts
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Metallising provides protetction

Metallizing provides both a barrier and a galvanic coating, providing aesthetic and performance in one
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Cost effective metallising

The cheapest method to produce metallised parts is to spray paint moulded parts. Costs improve by keeping both stages in house
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Headlight reflector problems

Whether for new applications or refurbishing classic car headlight reflectors, bring your business to the metallising specialists
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Spraying is most versatile metallising option

Spray painting onto plastics, glass and metal is the most versatile option for metallising, and we have both moulding and spraying facilities in house
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Custom finishes using metallising

With our modern facilities, we can metallise most surfaces with custom colours, or a gold or chrome effect
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Modern injection moulding machines can produce high shot weigths

Our modern injection moulding machines can produce a shot weight of up to 800g, so most items are achievable
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EMI Shielding coating available in the UK

We offer EMI shielding using aluminium, applied in a vacuum chamber at down to 1/2 micron thickness.
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POS items are our speciality

Our expertise includes items requiring finishing/manufacturing for the point of sale industry both on vacuum formings and injection mouldings
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Prototypes are a speciality at Dualmetallising

Prototype manufacture and finishing form an important part of our activities together with spray painting.
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Mirror manufacture

If you have a need for any type of mirror, contact us to see how we can assist you
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Window fashion industry on the rise

We have a range of special finishes for the window fashion industry, call in to see what make us special
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Vacuum metallising is a beautiful process

We have four vacuum metallising systems which technique, ranging from a standard type of deposition to state of the art plasma/in process silicone protection which has become the hallmark for automotive reflectors.
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Point of sale experience in formings and mouldings

Our expertise also covers items requiring finishing/manufacturing for the point of sale industry
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One stop metallised finish shop

Having both moulding and finishing systems allow us to offer a "one stop" destination for many of our customers.
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In house moulding and spraying for metallised plastics

Dual Metallising has over many years become a market leader not only in spraying polymers but also onto glass and metal products. http://www.dual-metallising.co.uk/spray-painting-plastic-parts.html

Growing market in promotional clocks

Promotional clocks are a growing business with many styles to choose from. We are able to supply most corporate colours and styles. Plus metallised finishes to resemble gold or chrome effect  http://www.dual-metallising.co.uk/prototype-promotional-products.html

Experts in producing vehicle reflectors

 Retroreflectors an ideal materials for use in the manufacture of bicycle and car reflectors. We share the technical details.  http://www.dual-metallising.co.uk/news.html

See our full range of services

Tool making undertaken through partnerships. Tools can be manufactured in Aluminium, P20 or fully hardenedhttp://www.dual-metallising.co.uk/plastic-injection-moulding.html

Enviable reputation for producing prototype and promotional products

Dual Metallising has an enviable reputation in the fields of prototypes and point of sale, producing parts on time, frequently, next day, in some cases while you wait.http://bit.ly/Mg8L2W

Customers own mouldings are the bulk of our reflector production!


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Paint/lacquer spraying is the most versatile form of enhancing plastic substrates and Dual Metallising has over many years become a market leader not only in spraying polymers but also onto glass and metal products.

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We also specialise in re-metallising headlight reflectors for classic and modern cars. In particular we have processed many MGF, Audi, Volvo headlight reflectors for cars that have failed the MOT test.
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We pride ourselves on providing the best service possible to our customers, offering competitive rates, we also have a fast turnaround capability which is vital to many of our clients.


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Please browse our website for more details on our services. If you require any further information please call us on 0121 708 2748 where one of our friendly staff will be happy to help.


http://www.dual-metallising.co.uk/

We can metallise on most inert substrates with the exception of Acetal polymers. Having both moulding and finishing systems allow us to offer a one stop destination for many of our clients.


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The Quality Policy, Manual and Procedures are subject to review in accordance with current Health and Safety, COSHH, regulations so that products are supplied in accordance with customer and applicable regulatory requirements.


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We offer different finishes for full production quantities down to single items.

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Please browse our website for more details on our services. If you require any further information please call us on 0121 708 2748 where one of our friendly staff will be happy to help.



http://www.dual-metallising.co.uk/

We have four vacuum metallising systems which technique, ranging from a standard type of deposition to state of the art plasma/in process silicone protection which has become the hallmark for automotive reflectors.



http://www.dual-metallising.co.uk/

Paint/lacquer spraying is the most versatile form of enhancing plastic substrates and Dual Metallising has over many years become a market leader not only in spraying polymers but also onto glass and metal products.




http://www.dual-metallising.co.uk/

Dual Metallising has an enviable reputation in the fields of prototypes and point of sale, producing parts on time, frequently, next day, in some cases while you wait.


http://www.dual-metallising.co.uk/

Please browse our website for more details on our services. If you require any further information please call us on 0121 708 2748 where one of our friendly staff will be happy to help.

http://www.dual-metallising.co.uk/

The Company is committed to Total Customer Satisfaction and will set, measure, action and review Quality Objectives to continually improve the effectiveness of the Quality Management System.


http://www.dual-metallising.co.uk/

The complete cycle of Plastic Injection Moulding Explained in Detail

Plastics are the cheapest raw materials available in the market. Plastic gets in to proper shape and size by the process of Injection Moulding. Plastic injection moulding is the process of manufacturing of plastic components. Plastic is an economical material which is used in various applications. Plastic Injection moulding is a process of forcing molten plastic by the application of pressure.

Plastic in the form of powder or liquid is fed through hopper into the barrel which is heated up to certain temperatures where it is mixed and then forced through a nozzle with the help of a plunger to the mould cavity where it hardens by cooling and sets to the configuration of the mould. The plunger is used to force the heated raw material through the nozzle. The plunger which is usually used is a ram or a screw-type. The mould is designed and made from steel or aluminium, and then precision machined forming the desired parts. Plastic Injection moulding is used to manufacture various parts, varying from small components to whole body of a vehicle. Manufacturing a mould is very expensive, so a mould is only used for mass productions. Moulding is the process of shaping a raw-material into the desired shape, by applying pressure. A mould is a hollow block which is filled with a liquid like plastic, glass or a rubber. Plastic injection moulding is one of the types of moulding which involves injecting a raw material into a pattern and applying certain factors like heat and pressure.

CYCLE OF INJECTION MOULDING

The sequence of events through which a raw material is converted into a finished part is known as the injection mould cycle. It includes the supply of granules being fed into a hopper to a heated chamber, where the granules are melted into the form of a liquid. Then a plunger is used to force the liquid through a nozzle to the mould. These processes are repeated again to form a cycle for mass production of products.

TYPES OF PLASTIC INJECTION MOULDING

The above described method is the conventional method of plastic injection moulding, although various other unconventional processes include co-injection moulding, fusible core injection method, injection-compression moulding, thin-wall moulding, powder injection moulding and many more.

With Plastic Injection moulding, a variety of plastic goods can be manufactured. Huge numbers of identical products can be manufactured with this process. A design engineer considers lot of parameters and venture specifications and designs accordingly. Manufacturing problems can be prevented right at the initial stage of design itself.

There are more than 30,000 unique products that can be moulded using plastic injection process. Its advantages include repeatable high tolerances, low labour cost, high production rates, easy to finish parts after moulding and the ability to use extensive range of materials. The major advantage of plastic injection moulding is that products with complex geometry can be made which is not possible in any other processes. As long as there is a need for plastic components of complex shapes and sizes, the business of manufacturing plastics will continue to grow.

The Company is dedicated to supplying products in a manner which meets the contractual requirements, that are delivered on time and with the ultimate aim of supplying zero defects.


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If you require any further information please call us on 0121 708 2748 where one of our friendly staff will be happy to help.

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How The Process of Plastic Injection Moulding Works

One of the most commonly used processes in the production of plastic items is the process most often referred to as ‘Injection Moulding’. There are several reasons as to why the process of plastic injection moulding is very popular, however one of the most common reasons given as to its popularity is the fact that as a means of goods production, the process can be used to produce enormous quantities of identically shaped plastic items of a variety of purposes. The goods produced by this process range from simple and disposable consumer goods to essential engineering components of high precision.

The Basic Process

In the most basic terms, the process of Plastic Injection Moulding involves the introduction of a certain material into the moulding machine (most typically via a ‘hopper’). The moulding machine is most commonly made up of a heated barrel (equipped with a reciprocating screw, usually driven by a hydraulic or an electric motor, which usually then feeds molten plastic into a temperature controlled split mould via a comprehensive network of gates and runners).

The polymer is melted by the reciprocating screw, which also then acts as a ram during the injection process. The shearing action of the rotating screw on the plastic assists in providing even more heat that can be utilised in this part of the process before the polymer is then injected into a mould which has been created in accordance to the required dimensions of the finished product desired by the client or customer. The pressure involved in the production process when the polymer is injected into the mould is extremely high, possibly even reaching 1000 atmospheres depending on the material being used in the process.

There are many companies and firms who specialise in producing important components and items made from plastic via the process of injection moulding. There is also a large number of companies which specialise in the production and supply of the moulds used in the injection moulding process.

The importance of the process of Plastic Injection Moulding is demonstrated by the fact that the service provided by the companies practising the process is in great demand by a considerable number of customers, including those in specialist industries such as aerospace and defence which require necessary specialist plastic goods and items produced by this process. The process is most commonly used in the production of the majority of thermoplastics such as polystyrene and nylon.

All our systems are fully automatic allowing for accurate repeatability throughout the process. Size capacities range from the smallest items to a maximum of 560mm x 960mm when rotating planetary , although it is possible to metallise larger items in certain circumstances.

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Dual Metallising Limited was established in 1982. We specialise in vacuum metallising, plastic injection moulding and spray painting. We offer different finishes for full production quantities down to single items.


http://www.dual-metallising.co.uk/

Paint/lacquer spraying is the most versatile form of enhancing plastic substrates and Dual Metallising has over many years become a market leader not only in spraying polymers but also onto glass and metal products.


www.dual-metallising.co.uk

We have four vacuum metallising systems which technique, ranging from a standard type of deposition to state of the art plasma/in process silicone protection which has become the hallmark for automotive reflectors.


http://www.dual-metallising.co.uk/

We also specialise in re-metallising headlight reflectors for classic and modern cars. In particular we have processed many MGF, Audi, Volvo headlight reflectors for cars that have failed the MOT test.

http://www.dual-metallising.co.uk/

Paint/lacquer spraying is the most versatile form of enhancing plastic substrates and Dual Metallising has over many years become a market leader not only in spraying polymers but also onto glass and metal products.
http://www.dual-metallising.co.uk/

Reflectors Keep You Safe On The Roads

It has been determined that almost all road accidents (no matter if they included motorcycles, cars, bicycles or maybe even huge lorries) take place during the night in circumstances of decreased visibility, for example fog. Therefore, it is essential that every vehicle used on the road ought to be specially fitted with a type of reflector to act as an added visibility preventative its an a virtually near guarantee that there's a reflector to fit every single model and make of motorcycle and car since in most cases the reflectors for vehicles such as this aren't constructed especially for particular models and makes and may very easily individually be stuck on or attached.

There's also lots of businesses specialising in the manufacturing of plastic items that along with producing reflectors in a selection of polymers (from standard ABS compounds to others for instance ULTEM, PPS and DMC which may have a really high level of heat resistance) for a large number of vehicles (manufactured using vacuuming or moulding production processes), also provide a re-metallising service for headlight reflectors of modern and classic cars alike. Companies such as these in many cases are asked to produce suitable reflectors for a lot of various makes and models of cars that have not passed their M.O.T. tests.

For bikes particularly, reflectors are usually manufactured as a moulded tile of transparent plastic, having a smooth exterior surface (in order to allow light for example from an approaching vehicles headlights to enter) whilst the back of the reflector takes the form of a range of angled spherical beads or micro-prisms. These reflectors make use of the principle of retroreflection to notify motorists towards the presence of the cyclist traveling on the road. Retroreflection happens when light is reflected back to the source with a minimum amount of light being scattered and lost in the surrounding area, making Retroreflectors an ideal materials for usage within the creation of car and bicycle reflectors.

When light hits the back of reflectors such as this (meaning the surface housing the spherical beads and micro-prisms) it will do so at an angle which is greater than the ‘critical angle’ (the angle of incidence above which total internal reflection can take place). Total internal reflection in this instance means (because of the orientation of the interior surfaces) the light is totally reflected out via the front of the reflector in the same direction it came from originally and immediately alerts the various other motorists towards the