About texturing
It is a metal microfabrication method that creates patterns on the surface of metal.
It is also called chemical corrosion (chemical etching) because it mainly dissolves metal using chemicals.
At a time when cloth was not yet available, tanning techniques were developed to make animal rawhide more practical. The process of adding wrinkles by kneading or squeezing is called "shibo-tsuke,'' and this pattern comes from the name "shibo".
In the case of plastic molds, "Shibo(texture) processing" is not limited to leather patterns, but also refers to corrosion processing of wood patterns, rock patterns, sand patterns, stipple patterns, and geometric patterns.
English expressions include texturing, graining, and engraving.
There are other techniques for adding patterns to the surface of molded products, but compared to the commonly used electroforming, electrical discharge machining, and precision casting, texturing has the following characteristics:
- Complicated and fine patterns that cannot be created by machining can be easily obtained.
- High degree of freedom in the patterns that can be selected.
- Delivery time is short.
- Re-processing due to design changes and repair of dents, etc. are possible.
Advantages
There are three advantages to texturing.
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01
Exterior
Plastic products originally have smooth surfaces and may give an expressionless impression, but by applying a texture finish to the product, it brings originality and adds value.
Types include "leather pattern'', "geometric pattern'', "rock pattern'' and "wood pattern'', which are texturing pattern often found on automobile parts to make them look more aggressive.
There is a somewhat modest and common "stipple pattern" that is often used in office equipment, housing equipment, miscellaneous goods parts, etc. -
02
Functionality
Textured plastic products are less likely to be scratched, or even if they do get scratched, they are less noticeable. In addition, the unevenness of the texture acts as a resistance, and can be expected to have an anti-slip effect.
At production sites, it reduces transfer irregularities such as weld lines and sink marks during molding, and depending on the application, it also helps improve mold release, leading to improvements in productivity including quality, delivery time, and cost. -
03
Environmental aspect
In some cases, the surface of the product does not require painting due to texturing.
By not painting, we can reduce the use of chemicals such as organic solvents contained in paints, and in turn, contribute to the creation of environmentally friendly products that lead to the SDGs.
Mechanism of texturing
Through texturing, various patterns such as sand patterns, rock patterns, wood patterns, leather patterns, and geometric patterns can be reproduced on the mold surface.
By repeating "transfer" and "corrosion" to reproduce textures that are closer to the real thing and have a realistic three-dimensional feel, you will be able to create a richly undulating and expressive texture.
Some simple texture patterns are repeated once, while others are repeated 10 times.
Approximately 80% of the entire texturing process is done by hand. Transferring, in particular, is a time-consuming process that requires craftsmanship and painstaking work.
The repeated process of patterning and corrosion is where each texture maker competes in terms of skill, and is where they can show off their skills.
Flow of texturing
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01 Cleaning
Remove oil and dust from the mold.
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02 Masking
Mask the sides and bottom of the mold that will not be processed with tape or paint.
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03 Transcription
The acid-resistant ink print of the pattern, which is the basis of the texture, is transferred to the mold surface.
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04 Corrosion
The mold surface is corroded using acidic liquid.
Corrosion removes metal and creates irregularities on the mold surface. -
05 Finishing
Blasting with alumina and glass beads.
Adjust the gloss and you're done. -
06 Inspection
Before shipping, inspectors conduct visual inspections and inspections using measuring instruments.
Principle of texturing
The processing principle is the same for reproducing any pattern, but if the pattern is complicated, the process of "transfer'' and "corrosion'' is repeated many times.
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Patterning process
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Etching mechanism
Processing process
*This is a complex pattern for automobiles, with "transfer" and "corrosion" applied three times.
Process① Printing
Print the textured version using a large printer.
Process② 1st transcription
This is the first transfer process.
Process③ 1st corrosion
This is the first corrosion treatment.
Process④ Second transcription
This is the second time of transfer process.
Process⑤ 2nd corrosion
This is the second time of corrosion treatment.
Process⑥ 3rd transcription
This is the third time of transfer process.
Process⑦ 3rd corrosion
This is the third time of corrosion treatment.
Changes in texturing depending on process
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Early stage of process
This is when the first corrosion treatment was completed.
Although you can see the basic outline of the texturing, it still lacks three-dimensionality and is far from natural leather.
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Mid-process stage
This is when the second corrosion treatment was completed.
Contains a detailed pattern to more faithfully reproduce the wrinkles found in natural leather.
Since the beginning of the process, it has become more three-dimensional and has a roundness similar to natural leather.
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Process completed
This is when the third corrosion treatment was completed.
Fine wrinkles and pores became visible.
The roundness unique to natural leather is added to create Japanese leather texture pattern, which is said to be the best in the world in terms of technique and quality.
This is the moment when "the work of expressing natural leather with plastic'' is completed, and "the product is brought to life.''
Texturing example
Textured products are used everywhere in our daily lives.
Here are some examples of texture processing that are used in everyday life.
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Automotive parts
The interior has a beautiful pattern textured around the instrument panel.
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Housing equipment
The surfaces of the bathroom floors and walls are textured to prevent slipping.
It also has the effect of improving drainage.
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Electronic/home appliance parts
The surfaces of plastic parts of electronic home appliances are textured for various purposes, such as improving appearance and feel, and preventing slippage.
Special texture processing
In addition to standard textured processing technology, our company offers two types of special textured processing designed to enhance functionality.
Contact
If you have any requests or consultations,
please contact us.
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