The Tooling and Manufacturing Process
Design and Engineering
- CAD Modeling: The process begins with creating a detailed design of the blister tray using CAD (Computer-Aided Design) software. This model includes all the dimensions and features of the tray, tailored to the specific components it will hold. A detailed drawing or 3D step file is required.
- Mold Design: Engineers design the mold based on the CAD model. This includes determining the type of mold, such as a single-cavity or multi-cavity mold, and ensuring that the design accommodates the material flow and cooling requirements.
Material Selection for Mold
- Choosing the Right Material: The mold itself is typically made from metals such as copper or aluminum. The choice depends on factors like the production volume, the complexity of the design, and the required durability of the mold.
Machining and Tooling
- CNC Machining: Using CNC (Computer Numerical Control) machines, the mold's basic shape is carved out from a solid block of metal. CNC machining provides the precision required for the mold to accurately reflect the CAD design.
- EDM (Electrical Discharge Machining): For finer details and more intricate features, EDM is used. This process is particularly useful for adding complex geometries and fine surface finishes that are typical in ESD tray molds
Finishing and Assembly
- Polishing: After machining, the mold surfaces are polished to ensure a smooth finish, which is critical to prevent any defects in the blister trays.
- Assembly: Components of the mold, such as ejector pins, sliders, and cooling systems, are assembled. These components are essential for the efficient functioning of the mold during the injection molding process.
Testing
- Trial Runs: Before full-scale production begins, the mold undergoes several trial runs. This testing phase helps identify any issues with the mold design or function, such as improper material flow or cooling, which can affect the quality of the final blister tray.
Final Adjustments
- Adjustments and Tweaks: Based on the results of the trial runs, necessary adjustments are made to the mold to ensure that it can produce ESD trays that meet all specifications and quality standards.
Production
- Injection Molding: With the mold finalized, it is used in an injection molding machine where the chosen plastic material (like conductive polypropylene or ABS) is injected into the mold cavity. The plastic solidifies into the shape of the tray, incorporating all designed features and specifications.
Video of Vacuum Forming
Vacuum-formed plastic trays are a practical solution for improving the functionality of your totes and handling containers. They offer components enhanced protection and can be used independently as handling aids or, more commonly, as inserts within tote boxes and containers.
Our vacuum-formed packaging inserts offer customisation options, perfect for manufacturing industries with specific needs. They improve handling processes, make part retrieval easier, and reduce the risk of damage. Our vacuum-formed conductive trays are suitable for clean rooms and applications requiring electrostatic discharge (ESD) protection.
Trimming and Cutting to Size
- Die Cutting: After the trays have been formed through injection molding, they are often connected by sprues (excess plastic from the molding process) and may have rough edges. A die cutting process is employed to trim off these excess parts and to cut the trays to precise dimensions. Die cutting uses a sharp, shaped blade set in a press to cut through the plastic.
- Laser Cutting: For more complex shapes or finer precision, some manufacturers might use laser cutting. This method offers high accuracy and can efficiently handle intricate cuts without risking damage to the tray material.
Quality Inspection
- Visual Inspection: Each tray is visually inspected for any defects such as warping, short shots (incomplete filling of the mold), or burn marks. The trays must also be checked for any residual particles that could contaminate the electronic components they are meant to protect.
- Dimensional Verification: Using tools like calipers or more advanced coordinate measuring machines (CMM), the dimensions of the trays are checked against the design specifications to ensure perfect fit and function.
- Static Protection Testing: Given the critical nature of their use, ESD trays undergo testing to verify their electrostatic discharge protection capabilities. This might include surface resistance testing to ensure that they meet the necessary standards for static dissipation or conductivity.
Packaging
- Cleaning: Before packaging, trays are often cleaned to remove any dust or debris accumulated during the manufacturing and handling processes. This step is crucial to maintain the cleanliness standard required for electronic component protection.
- Stacking and Wrapping: Clean trays are typically stacked in a manner that prevents them from being damaged or deformed. They are then wrapped or enclosed in protective materials that maintain their integrity during shipping. This might include shrink wrap, foam, or other buffering materials.
- Sealing and Labeling: The packaged trays are sealed to prevent any external contamination. Labels are applied, providing important information such as part numbers, material type, quantity, and handling instructions. The labeling ensures that the trays are easily identifiable and correctly handled throughout their supply chain journey.
Final Checks and Shipment
- Storage Conditions: Prior to shipment, the packaged trays might be stored in a controlled environment to protect them from temperature variations and humidity, which could affect their ESD properties.
- Shipment Preparation: The final step involves preparing the trays for shipment. This could include placing them into larger shipping containers or palletising them for bulk transport. The shipment method is chosen based on the destination and urgency of delivery, ensuring they arrive in pristine condition.
Custom e-ESD Packing Packing Trays
