1.
Hard Enamel
is a hard, glassy substance or opaque composition used in
coating the surface of metals and that grounded to powder
and applied by fusion on copper surface. It is similar to
what the dentist used on the outer coating of teeth. It is
natural mineral and has limitation for colors. For each color
ordered, a pin has to undergo one time direct heating over
1700F (800°C) before the powder can melt and crystallized.
That is, if there are 4 colors, the same pin has to undergone
4 baking process of one color after the other.
Features: preservable for over 100years
with ceramic-likened glaze; resistant to scratch, heat, humidity
& acidic chemicals, but limited in choice of colors. There
are tiny porous on surface due to natural impurities. Color
chart is available on “AOKI” or “FLOWER
VASE”.
Matching metal: is copper which
capable to endure similar high temperature but curved a little
after baking.
Production Process:
Customer Artwork > Develop negative film > Etching metal
Plate > Carving die/mold > Stamping design on metal
> Cutting out Design > Cleaning by acidic chemical >
Coloring > Baking > Grinding spilled enamel > Soldering
attachment > Polishing > 2nd cleaning
by ultrasonic water > Plating > Packaging
2.
Imitation Enamel
was invented in 1985. It is to meet the overwhelming demand
for hard enamel. The synthetic pigments give the gorgeous
appearance very close to Hard enamel but more shiny. The distinct
advantage is able to match Pantone color.
Features: Resembling 90% to Hard
enamel, non-resistant to scratch nor heat over 212F(100°C).
More shiny, colorful and surface smoother than Hard Enamel.
A distinct feature is the enamel layer is as high as the metal
rims. Color chart is available by Pantone® number (PMS).
Matching Metal: Copper, Brass
Production Process:
Customer Artwork > Develop negative film > Etching metal
Plate > Carving die/mold > Stamping design on metal
> Cutting out Design > Soldering attachment > Cleaning
by acidic chemical > Coloring > Baking > Grinding
spilled enamel > Polishing > 2nd
cleaning by ultrasonic water > Plating > Packaging
Similar to Hard Enamel above but:
- Soldering Attachment process moved forward to follow Cutting
out Design because the attachment only need to sustain about
212F(100°C). With attachment, it is easier to handle subsequent
Cleaning/Coloring/Grinding processes.
- Burrstone is replaced by spongy wheel in Grinding because
Imitation Enamel is comparatively softer.
3.
Soft Enamel
A. Stamped Copper / Iron:
uses paints pigment similar to those applied on car. Its cost
is generally lower than hard or imitation enamel. It takes
only about 100°C degree to dry the paints for 4 to 5 minutes
at an oven. The unique raised rims that render metallic feeling
are beloved by most buyers. Designs that need a thin border
or outline are perfect to apply soft enamel.
Features: are shiny but vulnerable
to scratch and high temperature. Hence, an extra layer of
epoxy (a doom of transparent plastic) is often applied to
protect the pins from scratching. The paint is thinner than
Hard/Imitation Enamel and lower than the raised metal rim.
Color chart is available by Pantone number (PMS).
Matching Metal: Copper(1.2mm+),
Brass(1.2mm+), Iron(1.0mm+)
Production Process:
Customer Artwork > Develop negative film > Etching metal
Plate > Carving die/mold > Stamping design on metal
> Cutting out Design > Soldering attachment > Cleaning
> Polishing > Plating > Coloring > Baking >
Filling Epoxy (optional) > Packaging
Similar to Imitation Enamel above but:
- Plating proceeds before Coloring to speed up process
- Fabric wheel is used in Polishing
- Epoxy may be added depends on order requirement
B.
Photo Etched:
Features: recess area is half thinner
than stamping ones (about 0.2mm vs 0.4mm). Color chart is
available by Pantone number (PMS). The metal border or edge
is at least 0.7mm.
Matching Metal: Brass(0.8mm+), Aluminum(0.8mm+),
Stainless Steel(0.8mm+), Iron(0.8mm+)
Production Process:
Customer Artwork > Develop negative film > Etching metal
Plate > Cutting out Design > Cleaning by acidic chemical
> Coloring > Baking > Wiping spilled paint by fabric
> Cutting out Design > Soldering attachment > Plating
> Filling Epoxy (optional) > Packaging
Etching is done on one metal plate about the size of A3 paper.
4. Stamping without Color
It is similar as soft enamel process but without enamel color
filling in. Options: Gold, Silver, Nickel, Chrome, Black Nickel,
Copper, Black Dye in either shiny, antique or 2-tone finishes.
Finishes can also be foggy, sandblasted or even granulation.
Plating is much thinner than paint. All stamped metal plate
must has electroplating on the background. The color filling
in is only optional to customer.
Features: Gives the genuine taste
of metal by metallic color & heavy weight. Most popular
applied products are coins, medals, pins & badges on events
such as sports games. The 3 dimensional effect cubic mold
is often ordered for this product.
Matching Metal: Copper(1.2mm+),
Brass
Production Process:
Similar to Soft Enamel above but:
- Omitting Coloring & Baking processes
- Epoxy is seldom applied
5. Printing
Epoxy must applied to these products to protect the underneath
printed colors and rendered glossy effect.
Features:
a. Offset – each color is mixed by different percentage
of 4 colors CMYK. Color resolution is about 200dpi. The color
is also named as Process color. Every etched plate with designs
must go through each of the 4 tinted rollers on printing machine
to produce the final artwork. Not every color has its process
equivalent e.g. metallic colors. That’s why spot color
is added sometimes. Glittering colors is also applicable.
Good for artwork with many and gradation colors.
b. Silkscreen – each color is premixed by paint manufacturer,
namely Spot color. Up to 280~300dpi resolution. Good for artwork
requiring precise, simple and high resolution of color e.g.
logo. PMS color chart applicable.
c. Pad Print – imitation enamel color pigments are used.
Around 175dpi. A thick metal die is required for sustaining
the rubber pad pressure. Good for pins with 3-dimension (thick
relief/recess) but not complicated designs. Products are colored
piece by piece versus batch processing of an array of pieces
on one plate via Offset & silkscreen. PMS color chart
applicable.
Matching Metal: Brass(0.8mm+), Aluminum(0.8mm+),
Stainless Steel(0.8mm+)
6.
Pewter Casting:
Features: The alloy of mainly Lead
& Tin. Normal combination is 90% Lead to 5% Tin plus 5%
metallic substances. Lead is heavy, vulnerable to breakage
and relatively dark in nature while Tin is softer, lighter
in both weight & color. Hence, the higher percentage of
Tin, the lighter, smoother & more white the product will
be.
| |
Elements |
|
| Pewter
Quality |
Tin
(Sn) |
Lead
(Pb) |
Misc.
Substances |
Melting
Point |
Features |
| Best |
90% |
5% |
5% |
240°C |
High tenacity,
light in weight & color, smooth surface, good for
high class product e.g. kitchen utencil, |
| Fine |
30% |
65% |
5% |
280°C |
Medium
tenacity & weight. Good for medium class ornament |
| Normal |
5% |
90% |
5% |
280°C |
Heavy,
good for item need minimal polish, medium to normal
class ornament |
| Pure Tin |
99.9% |
|
0.1% |
|
Shiny,
light, good for parts of finished |
| |
|
|
|
|
products |
Production
Process:
Customer Artwork > Engraving sample mold > Engraving
mother mold > Reproducing production molds > Pouring
liquid pewter into the mold > Hardening > Shaking Grinding
> Filing edges > Soldering Attachment > Machine/Hand
Polishing > Filling Epoxy (optional) > Plating >
Packaging |
