Industry

Flexographic printing has become very popular over the years due to its technological advancement. The flexo equipment has excellent functionality, rapid speed and produce high-end products that are appealing to clients. One would prefer reasonably priced goods for mainly personal, family, or other needs. The flexographic printing technology offers just that since total costs are usually low and profits are high. In this write-up, we look at the components that make up a flexographic machine.

Components of a Flexographic Machine

For label printing to happen, some components have to be present for the equipment to operate. They all pose similar features; hence it’s essential to understand whether you plan to buy or operate one. They include;

1. Printing Station

The flexo printing station should be smooth and firm, i.e., stable to ensure the printed images are not affected by any vibration. Each image should match the original one; thus, the printing must be consistent. Printing stations are available for each color. A variety of processes take place in this station, including;

• The anilox cylinder is fed through the inking system.
• Transfer of ink from the system to the plate
• Feeding of the substrate between the press plate and counter-pressure cylinder
• Passing of the substrate through the dryer and then taken to the next printing station

2. Feeding and Unwinding Station

The substrate is fed into the press plate using this component. It controls the tension, keeping it even throughout the process. The unwind system usually comes with a web guide that helps in cleaning the equipment. Treaters are an essential part of this feature as they treat substrates such as synthetics, doing away with bacteria or harmful substances that may be risky to people.

3. Drying Station

Every substrate passes through the dryer for the ink to dry. The same color can get applied again to achieve the desired saturation levels and get a solid color, or a different one can be used. Flexographic printing is known for its high production speed; hence, the intensity levels while drying should match the machine’s speed. Each application’s speed varies, but good machines will allow the press plate’s intensity and speed to be uniform. This station can include an Infrared or Ultraviolet (UV) fan for quicker drying.

4. Die Cutting and Converting

It is used to develop custom print shapes and labels. The designs you have dictate the process of die-cutting. They are converting aims at increasing the speed and performance of the die-cutting procedure. Products are produced in a sheet form, and this is common with narrow web presses. This entire process requires high-pressure levels, and robust, heavy-duty machines are needed to facilitate the printing and avoid breaking down.

5. Outfeeding and Rewinding

This is the final stage of the printing press, and the substrate exits at this point. The tension is still controlled by sensors, which play a significant role in enabling the leaving process. Rewinding helps remove the waste materials out of the system, and the end products are kept in rolls to be inspected before selling them out.

Conclusion

Each component of the flexo machine plays a huge role in the printing process. The points above will help you understand what they are and how they work for more effortless operation.

Several different industries are utilizing CNC machining. That’s because it reduces overall costs and labor works. The process is highly efficient, and creates products within a short time. While CNC machining could be used in a variety of applications, your machine can experience glitches sometimes.

Keep reading this article as it explains different ways you can spot bad CNC machines.

How to spot a Bad CNC machining service

1. If the Tools are Not Aligned Properly

A CNC machining could have issues starting if your tools are not aligned properly. A sign could be having shapes that are not correct or featuring some dimensions that are above the tolerance minute is another sign. To control this, you need to mount the tool properly on the machine. You need to properly check the chuck alignment. Also, Look at the tool and the tailstock before you start your operations.

2. Clamping Improperly

A machine that isn’t clamping properly may lead to your products having a poor surface finish. It can also damage your tool holder in the process of production and an increase in the vibration of your cutting tool and other work piece. To avoid this, you need to be sure your foot-switch and your hydraulic pump are running. The cutting took the axis and the rotating axis needs to be checked too.

3. Chatter Error

Chatter refers to a solution where your machine or your workpiece uncontrollably vibrates. If you do not set your machine properly, this is bound to happen. You need to install your tools accurately to prevent this sort of horrible CNC machining service. All errors obtained from this chatter could damage your machine. Therefore, increasing or reducing the feed rarely helps to control the chatter. You can also use positive chip breakers.

4. Horrible Surface Finish

If you use your CNC machining service and end up with a poor surface finish, your clients would get turned off. This always happens whenever you have a very high feed rate. The feed rate could be too much for your nose radius on your CNC machining. You need to work with low speeds on cutting and also a reduced amount of shearing action. These could all contribute to your very poor finish issues. For proper control purposes, you need to reduce the feed rate and make sure you increase the rate of cutting. You could make use of a larger nose radius. Also, Don’t forget to use a positive chip breaker; this would help your optimal surface finish to look better than before.

Conclusion

No one wants to make use of a bad CNC machine as it may damage the whole production process. To prevent such horrible situations from reoccurring, make sure you install your CNC machine properly. This way, you get to avoid bad Surface Finish, chatter error, and improper clamping. Make sure you align your tools properly; the organization is essential. Following this guide will enable you to enjoy your CNC machine and also your overall costs, while creating high-quality products.

When compared to manual machining services, CNC machining services have a lot of benefits. CNC machining is often referred to as a production process that involves the use of a CNC machine. This machine dictates and controls the movements of machinery and tools found in factories and industries.

There are quite a several factors surrounding decisions regarding CNC machining and manual machining services; Keep reading to find them out below;

Top benefits of using CNC machining

There are many reasons why CNC machining services are far better than manually controlled machining services. Some of the advantages and top benefits of using computer numerically controlled machining services include but not limited to:

1. Accuracy

Accuracy is one of the major reasons why CNC machining services should be adopted. With it, the accuracy level becomes higher than others expected. The entire process involved is precise. This means that any operation carried out can yield the same preferred outputs with ease, regardless of the number of times it’s done. The manual machining service on the other hand may not be able to produce the same result as expected.

2. Increased production speed and efficiency

Since tasks completed with a CNC machine are directly controlled by a computer, they can be calibrated to fit a specified output. These specifications do not change unless the operator decides to recalibrate. This preprogrammed feature in CNC machining allows for an increase in speed during production.

Also, since the program does not change, there is a tendency for increased quality of manufacturing that can be sustained until the program is complete. Due to it being automated, it can also run for longer durations thereby being more efficient. Unlike CNC machining, manual machining uses human energy. This can’t be trusted as humans can easily get exhausted hence, break down at some point.

3. Increase safety

One other important reason why CNC machines are still in use is the increased safety feature it has. Operators of CNC machines need not be close to it during production. This means that in the cause of damage, there are fewer chances of humans getting hurt or injured in the process. While in manual machines, operators stand at a higher risk of getting badly affected by machines.

4. CNC Machining is Affordable

As in the case of every other technological advancement, CNC machining is much more cost-effective. This is because one operator can control multiple machines. Also, only a few operators are needed to handle an entire CNC machine facility. And since the output is usually accurate, there won’t be many occurrences of wastage regarding raw materials. In the case of manual machining, there’s usually a lower level of productivity hence the need to employ the use of more persons.

Conclusion

From the information above, it’s clear that the CNC machining services perform better than its counterpart. Products are manufactured in larger quantities and also within a short time. CNC machining services are the best for anyone hoping to get better at production!

The Romans invented lead pipes about 1000 years ago. These structures made it possible for them to carry water from point A to B. Try to imagine how easy their life would be if they had modern fiber optic cables. Such structures would carry telephone calls coupled with emails around the world. And this would happen in just a few seconds.

The light source of a fiber optic illuminator is bright. Some optics are useful in focusing light into a fiber. Consequently, sources need to be bright such that quartz halogen is the commonly used element. Some manufacturers of fiber optics lighting cables choose to use xenon metal lights.

Features of the fiber optic lighting technology

An optical fiber refers to a reliable and flexible fiber made using a drawing glass. All too often, optical fibers are used to move the light from one point to another. Consequently, they are also referred to as fiber-optic communications cables. These cables work by permitting light transmission over relatively longer distances. They also serve fiber-optic communications by transmitting light over paths with longer distances at slightly high bandwidths.

Why do professionals in the industry use optical fiber for lighting?

If you are wondering why many professionals use fiber optics, it is because signals often travel along with them. Besides, these fiber optic cables are highly immune to any form of electromagnetic interference. This happens to be an issue several metal wires suffer.

Fiber optic lighting cable is also ideal for illumination as well as imaging. They can be wrapped in bundles. Consequently, they become handy in carrying light to confined spaces. Tailored designed fibers can also be utilized in a variety of applications. Some include fiber optic sensors as well as fiber lasers.

The operating mechanism of a fiber optic lighting cable

Fiber optic cable lighting works as the medium that allows light to move down the cable by bouncing off the walls. Just like a bobsleigh, every ounce of photon bounces into an ice run.

After that, you should expect a significant beam of light to travel through a pipe of glass and leak out of its edges eventually. However, if the light hits the glass, then it will reflect once more. This is as if the glass was a mirror. The phenomenon is referred to as total internal reflection. That is one of the elements keeping light inside the pipe that projects it to your space.

Optical cables for lighting look like the fibers often used in communication. They are used to transmit light at relatively high speeds. Such fibers have a core used to transmit light. In addition, they have a cladding that traps light into the fiber’s core.

And unlike the fibers used in communications, lighting fibers use relatively larger cores that come with small claddings. These claddings can maximize light and enhance illumination.

Final Thoughts

Providing you with another tool you can use for creative illumination in the long run, you can grasp the technology behind a fiber optic lighting system if you comprehend simple concepts. For instance, fiber optic lighting is still a preferred electrical contractor following its complexity.

The plastic industrial sector is revolutionizing, and polytetrafluoroethylene (PTFE) filler, a material mostly used in cookware and protective clothing, is becoming prominent in many industries that prefer this versatile material. It is commonly used in manufacturing and telecommunications industries, to mention a few. Teflex 40%-60%bronzePTFE filled sealing bears unique characteristics that contribute to its usage in different industries.

Pure PTFE has low friction. This enables the material to withstand substantial temperature changes, which makes it perfect for cookware, including nonstick pans. It is also very dense and flexible.

Plus, the feature enables this material to be used in coating machines making them more durable. It is also very unreactive and insoluble; using it in food manufacturing industries is safer. With all the material’s qualities combined, it can be practically used for a wide range of applications in the industrial sector.

PTFE is also known to work more effectively when a filler is added. A filler is highly recommended since PTFE can easily creep and deform under heavy loads due to its flexibility.

The common properties that are drawn from adding fillers are improved thermal conductivity for materials that require proper dissipation of heat. The most common filler is glass, among others, each with the advantages it confers to particular applications.

1. Glass

Using glass as a PTFE filler reduces flexibility hence low chance of creep. Increased glass content also enhances the resilience and strength of the material.

That said, a PTFE material filled with glass is coarser than the virgin one. The only similarity that both convey is that they work under the same range of temperatures, and both are chemically inert.

2. Carbon

For this specific type of PTFE material, carbon is added as a filler in two ways: in fiber or powder form. In comparison with the virgin one, this benefits from improved compressive strength and low chances of deformation. It also has better wear resistance. Carbon being highly conductive, it can be used in materials that require high thermal conductivity than PTFE alone.

3. Graphite

This is similar to carbon except that it does not have better wear resistance. Graphite is known to lower the coefficient of friction when used in product making. A PTFE filled with graphite, therefore, has excellent self-lubricating properties. Lastly, graphite can be used alongside glass and carbon fillers to bring about the best results.

4. Stainless Steel

Stainless steel is added to PTFE in powder form, enabling it to acquire a lot of strength, coupled with the ability to withstand enormous loads simultaneously. Stainless steel filled PTFE works excellently under high temperatures hence suitable for applications using steam and hot liquids. It is ideal for a good number of mechanical uses. It is also tough to wear out; this is a good quality, which is a disadvantage to closer surfaces.

Final Thoughts

A virgin PTFE is useful on its own since it has its unique characteristics. The features can be improved by using fillers. The choice of fillings depends on the application of the PTFE. The quantity chosen also determines the quality of the material.

Rapid manufacturing or prototyping and some of the technologies including, moulding, extruding casting among others is simply using software to ease up and quicken the manufacturing process and involves CNC machining and 3D printing while traditional manufacturing refers to the principles that aid in a certain number of products and reserving in case of rise in demands or shortages in the near future. With a 3D printer you can enjoy fast turnarounds at a relatively lower cost. Although CNC machining uses subtractive manufacturing hence a lot of waste, it still has a key role in manufacturing processes. Rapid manufacturing overtakes traditional manufacturing in several ways which includes:

Even less waste.

Additive manufacturing gets rid of unnecessary material waste hence saving on the material cost this is because it adds product from scratch. 3D machining takes the elimination of secondary machining to a higher level. Less waste will ensure that your production process is cost efficient.

Manufacturing and assembly at once.

This helps in combination of manufacturing and assembly into a single process. This evades the need to create parts individually then assembling them later on and instead obtaining multiple components at a time.

Rare shape making ability.

One can create any shape be it hollow spaces and honey combs that can maintain stability while decreasing the weight hence once more 3D printing can be used as powder metallurgy.

Complexity is free.

The more complex a part is the easier and faster it can be made through the additive manufacturing method. 3D printing gives room for complex geometries since all you need is a CAD file.

Little skill manufacturing.

 This has been certified in that children in the 3^rd grade have created their own parts by the help of 3D printers while professionals take high concern on the complicated parts with specific parameters. Some machines can run for hours without human intervention. Since little human involvement is allowed, the risk of human errors is eliminated meaning that quality is ensured.

Little lead time.

After completing stereolithographic file, instead of waiting for ages for a prototype to come engineers can create a prototype with the help of 3D printers. In a fast paced market, prototyping requires fast production means. A good example is the plastic market. In the plastic industry you need to have a short production cycle if you are to survive. Injection molds used to take ages especially if they were made from hardened steel, not to mention how expensive steel is.

 Few constraints.

With the help of additive manufacturing one can create something exactly how he or she imagined it. You can further replicate your design to come p with identical parts.

 However, rapid manufacturing has some disadvantages which include; post-processing is needed since it may have low quality than other manufacturing methods, poor mechanical properties especially on the layering, it is almost always cost prohibitive since it is not always effective, no mixing allowed and it is slow and niche among many more.

Light Emitting Diodes are among the newest innovations of technology that are related to the display of screens. LEDs produce high energy, which is efficient and brighter than the LCD screens. For decades, China has grown to become a global leader in the industry market, which deals with LED products’ flexible selling. The Outdoor led display china market is continuously increasing because many companies have adopted the technology, especially those who deal with media platforms of advertisements. Also, the rising technology is in high demand because it’s environmentally friendly, durable, and efficient; hence its growth in the Chinese market.

Why would you need an Outdoor LED Screen?

If you need to advertise, do promotions, or inform an audience, you need to purchase an Outdoor LED display. Its installation is easy, and it can be done anywhere. Apart from the many benefits they have, outdoor LED displays are manufactured in various sizes; hence, they fit a customer’s preference according to their need. People can use outdoor LED displays to make giant billboards, banners for advertising, signboards, perimeter LED boards, and LED video walls.

Types of the Outdoor LED Screen from Manufacturers in China

The most popular LED screen types in the market are the P6 and P10. The display pixel pitch of P10 is 10mm, while that of P6 is 6mm. Both f these technological products are commonly used in outdoor advertisements because they provide a perfect experience in viewing, and they are also economical. When the output is put at a distance of between 6-10m, the view is apparent; hence, they become the best outdoor advertising options. Both LED products’ brightness offers over 7000 CD/Sqm bright output, which is considered perfect when performing outdoor advertising.

Where you source the Outdoor LED screen from Manufacturers in China

As mentioned earlier, China is the hub and manufacturing producer of many things that can be shipped quickly globally. If you need to purchase an outdoor LED display, you search them by visiting China or browsing via commercial sites that deal with B2B Chinese sales. Many trade fairs occur in China yearly, and some offer specific services while others are general. Such will be suitable for you, especially those who are industry-specific, because you will easily find the LED displays you require.

When hunting online for the LED factories, you can head to Alibaba.com, which is considered the most popular in offering resources. E-commerce sites are reliably, and anyone can use them efficiently. You have to make registration before you proceed to make contact with the LED manufacturer or supplier. Some of the websites’ suppliers are verified; hence, they are vouched to be qualified, but you have to guard yourself against getting robbed through fake manufacturers. Another option you might need to consider includes an agent who can help you search for the right company that offers the right products for a suitable price. However, you need to be prepared about paying a small fee for the services that they provide.

Novastar J6 is the latest high-performance video processor for multi-screen switching and splicing with enhanced image processing power. Based on a powerful FPGA (Field-Programmable gate array) processing interface, the Novastar J6 supports instant and seamless switch of input source and transition effects, for instance, fade and other commands providing a more flexible screen layout. It supports up to 8 inputs with a resolution of up to [email protected] The Novastar J6 has proved to be the best in the market and has met broadcasting standards for all stage screen controller functions.

The Novastar J6 multi-splicing screen processor is also equipped with the smart control software V-Can designed to create more splicing effects, quality image, ultra large loading ability and flexibility to improve and satisfy the user.

Novastar J6 Multi-Screen Splicing Processor Features

• Compatible with most industry-standard input connectors in the market. One single Novastar J6 supports video inputs divided into four groups with up to 8 connectors DVI, HDMI,3G-SDI, DP. 
• Dual system mode which allows for switcher or splicer mode depending on application requirements. 
• The Novstar J6 has multiple windows display. It can support up to six 4Kx2K windows with each window supporting cross connector output. 
• HDMI connector for monitoring output. It supports monitoring both single and multiple input sources PVW or PGM. 
• The Novastar J6 display control functions allows you to freeze or blackout the screen by clicking one button.
• Seamless EDID management. The Novastar J6 supports resolution management for input connectors like HDMI, DP, and DVI to provide professional image quality.
• Transition effect where on splicer mode, the J6 will support settings of transition effect for source switching while on switcher mode, it supports effects duration and take-effect settings. 
• It has built-in seven windows templates.
• It has multiple operations mode. It is operated either via the V-Can smart control software, C1 event controller, or the front panel. 
• GenLock for synchronization between video signals.

Technical Specifications

Input Connectors:

• DVI – with an input resolution of up to 1920×[email protected] and downward compatible as well.
• 3G-SDI- Input resolution of up to 1920×[email protected] and downward compatible as well.
• HDMI 1.3- Input resolution of up to 1920×[email protected] and downward compatible as well.
• HDMI 1.4 – Input resolution of up to [email protected] 
• 1 Input resolution up to 4k X 2K @ 30Hz .

Output Connectors:

• DVI -4 groups with two connectors for each group for mosaic output. Each group consists of the main connector and a backup connector. 
• HDMI for output monitoring.
• USB type A & B- Type A connects to the PC for device control. Type B is a reserved connector. 
• Ethernet connects to the PC for communication or to a network via an IP.

Other Technical Specs:

• Power Consumption – 50W
• Temperature- 0°C~60°C
• Weight – 3.8Kg

General Users Guide.

• The on and off button is found on the front panel.
• Also on the front panel is the windows button. 

On indicates the window is open. 

Dim indicates the window is open but the input sources cannot be detected.

Off is an indicator that the window is shut down.

Flashing indicates that the window is being edited.

• LCD screen displays current device status and settings.
• The knob is used to adjust or select operations functions.
• The freeze button’s main function is to freeze and unfreeze the output image.
• ESC button whose function is to exit the current menu or cancel the operation.

All manufacturing processes must involve the use of tools to make parts and prototypes. The choice of tooling will determine the pace and effectiveness of your production process. Tooling is not a one fit for all issues, you must consider the cost, volume, and time required to produce. With the current market shifts, manufacturers are forced to incorporate rapid prototype tooling since production cycles should be short. Most people are not aware that tooling has three distinct categories; prototyping, bridge tooling, and production tooling. As the names suggest, each of the classes has different components and applications.

Rapid Prototype Tooling

Rapid prototype tooling is a vital part of any manufacturing process. Rapid prototyping started in the 1990s, where engineers used plastic injection to develop prototypes. The nature of the market requires manufacturers to shorten the production cycle to produce a lot quickly. Rapid prototyping ensures that you get customer feedback and act on it fast. The main aim is to reduce production costs by using less durable tools capable of fast output. It is a race against time, and convectional tooling techniques are slow and costly. Traditional tooling uses metals such as steel, which has a long life cycle but very expensive. Rapid prototyping uses aluminum because it is relatively cheap and does not affect the quality of the production process’s materials. The validation process involves low volume production and does not require complex tooling. Rapid prototype tooling helps you save on time and cost.

Bridge Tooling

Bridge tooling is simply the transition between a prototype and the final product. Bridge tooling is used to set the pace for full production. The requirements for this stage are not as robust as those used in the production process. Manufacturers used bridge tooling for initial production as they set up production tooling. The two can supplement each other to ensure the smooth flow of the production process.

Production Tooling

After a prototype has undergone testing and is fit for production, production tooling is used to assemble the final product. Of the three, production tooling is the most delicate since it focuses on the final product. This means that tooling is expensive; hence a hefty investment should be geared towards it. More time should be allocated when using production tooling to ensure that the final product maintains functionality. You have already invested a lot in prototyping and bridging; a single miscalculation can see all your efforts go down the drain.

Benefits of rapid tooling

Rapid tooling has revolutionized production cycles, making them much shorter and cost-effective. Here are some of the benefits that accrue as a result of rapid prototype tooling;

• Design innovation
• Time-saving
• Fast production
• Cost-saving
• Quality assurance

Conventional tooling requires a lot of time to complete production, and the materials used to make these tools are expensive. Rapid tooling aims at shortening the production cycle and reduce the cost of production. Industries using rapid prototype tooling can cut down the cost of production by a staggering 50%

CNC machining is used to make customed parts with tight tolerance and strong strength. In fact, it is a cost-efficient and fast way of manufacturing production parts and prototypes. Optimized designed cnc parts help reduce production time and save cost. These are tips for optimizing the design for various CNC parts.

Round Internal Corners

Most CNC machining tools like milling cutter and end mill leave rounded internal corners. You can reduce the radius by using a machining tool with a smaller diameter, but it needs a smaller tool to eliminate the material. This is usually done at a lower speed to minimize the risk of tool breakage or deflection. This will result in longer machining time.

Thus, it is advisable to add an internal corner radius and use the same radius for internal edges. In this way, you can eliminate the tool changes, increase run time, and adds complexity.

Do Away with Deep Cavities

End mill tools have a limited cutting length that works best for cutting cavities. You can minimize the cost and suggest limiting the depth of the cavity to ensure you get the desired tools. Otherwise, you will increase the manufacturing cost as you require multi-axis CNC systems and special tooling. If you need a larger cavity, then you design CNC parts with variable cavity depth.

Avoid Thin Walls

You should note that CNC parts with thin walls like to chatter. Unfortunately, this reduces the machining speed. Moreover, thin walls can result in distortion that makes it difficult to create accurate parts. If you do not take care of this, it may result in extra cost and time. You can keep the machining costs low by increasing the thickness of thin walls.

Optimize Depth of Tapped Holes

Concerning tapped holes of CNC parts, you should consider increasing the length of thread in a hole to hold the bolt a bit tighter. You should note that only a few turns are required to do the work. In fact, going deeper increases time for tapping operations. Therefore, you should avoid threading a hole more than three times its diameter.

Avoid Tight Tolerances

You should note that not all surfaces of CNC parts are important to its function. Therefore, parts with tight tolerances are expensive to manufacture. That is because they increase machining cost and time. It is advisable to avoid tight tolerances and only assign them on critical surfaces and features. Features or surfaces that are less significant can be machined according to standard tolerances.

Minimize Small Features

Certain features such as micro-holes increase machining time and machining difficulty. Thus, you should avoid them unless they are important.

Reduce the Complexity of CNC Parts

You should note that machining several simple parts is cheaper than machining a single complex part. That is the case for parts with tapered holes and deep pockets that need several hours of machining to get rid of the material. As a result, most CNC machining services charge more for complex parts. That is because if mistakes happen, it is expensive to redo complex parts than it is the case with redoing simple ones. Therefore, you should consider splitting up complex parts into various simple parts that can be assembled.