1.Customer provides the 3D drawings or product’s sample.
Vacuum forming is one of the common methods of processing plastic materials. From the beginning, we prefer you provide us the 3D drawings or samples of your products. STP, STEP or IGS are the first choices. Of course, DITAI has a professional designer and engineer, if you wish, we can help you create or completer your design or ideas.
2.Giving you the suggestions and related quotations.
According to different applications of the products. The material we matched for you during vacuum forming is also different. That is great if you have your own choice of the raw material, or we can match the most suitable raw material for your reference. Here the introduction of the different plastic raw materials. Once we get your drawings, we will evaluate this and give your our best suggestion and quotation.
The material for the mold is usually Aluminium. Because this kind of mold is very durable and can be used for a long time. Of course for some special situation, customers will choose the wood mold for making the products. But the wood mold is not what we suggest you do it. To ensure the product’s quality is superior. We have to produce a perfect mold at the first. Therefore DITAI has its own mold making machines and own mold engineers who have own 20 years of experience in vacuum forming technology. This makes us can control the mold cost, delivery time, and the quality in a very good condition.
Also for the mold, DITAI will have a warranty service for you. Once the mold is broken or can not use in here. DITAI will make a new mold for you freely.
4.Raw material extrusion.
Also, a good quality raw material sheet will influence the product’s quality too. The raw material sheet production is through machine extrusion. Then the vacuum forming sheet will have a good performance, the impact strength is very good. Some raw material sheets can be used at lower temperatures. For now, DITAI also establishes a raw material sheet production line. And our target is to have 3 production raw material lines, then we can produce all the raw materials by ourselves and can control the quality of the raw material at the beginning.
The raw material sheet size, glossy level, thickness, color, etc can be controlled here. So is the cost.
5.Vacuum forming Production Steps.
● The vacuum forming aluminum mold is installed in the vacuum forming machine, then our worker will heat the mold to a suitable temperature.
● After the mold is ready, we will put the raw material sheet or roll it on the vacuum forming machine table.
● Then we will use the heater into the vacuum forming and heat the raw material into good condition and suitable for vacuum forming.
● Once the raw material is ready, the vacuum forming machine will push the mold and make the mold touch the raw material until it totally covers it.
● When the raw material touches the mold completely, the machine will vacuum forming the mold at the backside. And the air between the mold and plastic is evacuated. This makes the raw material touch the mold perfectly.
● Finally, we will use an air cooling machine on the vacuum forming to cool the raw material, then separating the finished plastic product and the mold. Once everything is ready, our worker will take the product out of the machine. The vacuum forming process is done.
For now, DITAI has 14 sets of vacuum forming machines, one machine is the full automatic vacuum forming machine. These machines are suitable for producing different sizes of customized plastic products. The biggest plastic size we can produce is 4000x2000x1000 for now this is the biggest vacuum forming machine in Dongguan and our CEO designer and DITAI create this machine. Based on our workers’ over 10 years experience in vacuum forming technology, The temperature and delivery time can be controlled strictly here.
After vacuum forming. All products are semi-finished products. We will need to use CNC machines to cut the extra plastic material on the vacuum forming parts. The CNC machines can be divide into 3 axes CNC machines and 5 axes CNC machines. These machines are used for cutting the different shapes of plastic products. Usually, some complicated plastic parts need to use 5 axes CNC machines to do the treatment. The features for 5 axes CNC machine can cut the plastic parts at any angle or location. Also, the size accuracy and working efficiency are very good.
For now, the DITAI company has 13 sets 3 axes CNC machines and 7 sets 5 axes CNC machines. We can meet you with any order quantity request.
7.Polish, Burring on the finished products.
To offer you the perfect products, we have well-trained workers in quality testing and burning.
The average working experience from them is around 5 years. Usually, all products need this treatment to ensure the product when the customer receives is in very good condition.
8.Extra treatment: gluing, paint and silk-screen.
Some products also need gluing, paint or silk-screen treatment. These can improve the whole product’s beauty and appearance. and DITAI also has a related department for this treatment.
Once the products are finished, we have well-trained engineers or our sales will test the product’s size, color, and whole quality to ensure the product’s quality arrive at our customer’s hand are satisfying.
10.Package and delivery.
According to the different product’s requests, we will match different packages for these. Like carton box, wood box, or pallet, etc…If you wish, we also can arrange the shipment for you to save time for this order.