Materials need: dispensing silicone ,molding Silicone , silicone catalyst, thinner, color pigment, hotmelt film, position paper (high or medium adhesion)
Machines need : vacuum cabinet, 12-color automatic dispensing machine, automatic baking machine, vulcanizing machine, Freezer, mold
Step 1:Set up the needle path on Logoshop software on the computer.
The specific operation method is as follows:
Load the molding design artwork into Logoshop software.
------Click "Machine Pointing" and align it with the "cross".
-------Click the "Polyline" command on the left side of the software menu.
-------Select the color to draw the path of dispensing needle 1.
When drawing the line, keep the needle in the middle position. After drawing, press the right mouse button OK to save;
-------Select the color to draw the path of dispensing needle 2,3... repeat the same way and save it.
-------After all the paths of the needle are drawn, save it and download to USB driver.
-------Insert the USB driver into the operating controller of the dispensing machine and press the number "1" ,then select "ENT". After the data is loaded, you can unplug the USB driver.
Step 2: Set the controller parameters of the dispensing machine.
The controller is used to adjust the needle running position ,needle height, and disensing amount,running speed.
The operation method is as follows:
-----First adjust the needle No.1. Use the directional keyboard (up, down, left, and right keys) on the controller to align the needle completely with the center point on the mold.
-----Then adjust the needle height and running speed.
----- Adjust needle No. 2, No. 3... same way as the needle No.1
How to operate the controller requires more practice on site to understand.
Step 3: Prepare the silicone and release bubbles:
---- Dispensing molding silicone mix with catalyst AS-A50 at ratio 100:2, add 5-10% color pigment. Mix well. Can add some silicone thinner if the silicone not fluid enough.
--- Vacuumize the mixed well silicone in the vacuum machine about 3 times, 2 minutes each time. Make sure the silicone without air bubbles.
---Fill the vacuumed well silicone into the material pipe of the dispensing machine and vacuum it once again, then install it into the dispensing machine and test whether the ink can be dispensed smoothly.
Step 4: Dispense the silicone in the mold
Use the dispensing machine dispense the silicone in the mold, we start dispensing from needle 1 ,Needle.2...to the last needed needle by order and color requirement.
Tips: If you find the come out silicone not properly( too full or too thin), you can adjust the pressure or needle running speed.
Most of the time, you only need adjust the pressure when do single color badges, for multi-color you can adjust the needle running speed.
Step 5: Bake the dispensed mold in the baking machine
After finishing all color dispensing in the mold, put the mold into the automatic baking machine to bake dry and cooling down .(temperature is about 190℃ for 120 seconds, cooling time is about 45 seconds).
TIPS: If No color overlap in the design, after finishing all color dispensing, directly put the mold in the baking machine curing and cool.
If have color overlap, you need bake the mold after finishing each color dispensing .
Because we can't overlap dispense the silicone on top of last layer when it didn't cured enough.
Step 6: Use automatic vulcanize machine curing the silicone
For the bottom layer of the badge, you can directly use the dispensing machine(without a needle) dispense the silicone on the mold .
We also can do manual filling.
Bottom layer molding silicone suggest use item AS6440 (Higher viscosity than dispensing silicone and good performance.)
---Fill the molding silicone onto the mold that has just been dispensed and vulcanized,
---Put on the hot melt film
---Cover the mold with a high-temperature fabric and put it in the vulcanize machine for high-temperature vulcanization.
The upper mold temperature is 100℃, and bottom mold is 130℃. The curing time is about 20-40 seconds, which depends on the actual situation of the customer;
----Take out the vulcanized mold and put it on the freezer to cool it down;
----Release the badges from the mold and remove the wast .
--- Use high or medium adhesive position paper to transfer the silicone badges from the hot melt film. (small letter suggest use high adhesive paper,big letter suggest medium adhesive paper).
It's Done!
Step 7: Use press machine heat press the badges on the fabric.
Heat press temperature at 160℃, 15 seconds
(it is recommended to press both sides for better results)