吸塑工藝流程

一、客戶發出詢價請求：途徑一打電話詢價，途徑二發傳真詢價，途徑三發Email詢價，途徑四通過網絡聊天工具詢價。客戶必須提供吸塑制品的長、寬、高和所用材料(liao)的厚度(或克重)、顏色和型號（PVC、PET、PS、PP），產(chan)品數量和生產(chan)周期。

二、業務部門報價：吸塑制品單價的高低跟以下因素有關：吸塑制品的長、寬、高和吸塑成型的復雜程度；所用材料的類型、厚度和顏色；吸塑產品的(de)后道加工(gong)工(gong)藝（折邊、打(da)孔、封邊等）、訂單數(shu)量和訂單周(zhou)期。報(bao)價(jia)員會(hui)以客(ke)戶(hu)的(de)樣(yang)品和描述(shu)有(you)一個最初報(bao)價(jia)，最終報(bao)價(jia)會(hui)在打(da)樣(yang)之(zhi)后報(bao)出。

三(san)、電(dian)腦(nao)設(she)計(ji)：客(ke)戶對于(yu)報價基本認(ren)可后，會將(jiang)要求、實(shi)物或(huo)是(shi)吸(xi)塑樣(yang)品交到(dao)業(ye)務部(bu)，生(sheng)產(chan)調(diao)度(du)會要求電(dian)腦(nao)設(she)計(ji)部(bu)將(jiang)客(ke)戶的(de)(de)實(shi)物掃描并結合印(yin)刷(shua)品的(de)(de)設(she)計(ji)，制(zhi)作出(chu)吸(xi)塑制(zhi)品的(de)(de)平面設(she)計(ji)圖

四、吸塑打樣：客戶認可電腦設計稿后，生產調度會根據吸塑產品的復雜程度決定采用哪種方式開發模具（石膏模、銅模、鋁模），開發周期3-5天。吸塑打樣以石膏模打樣居多，其操作步驟是：1.先將實物用手工泥糊出成型輪廓；2.放到吸塑打版機上成型泡殼毛胚(pei)；3.用(yong)(yong)配好(hao)的吸(xi)(xi)塑(su)專用(yong)(yong)石膏(gao)倒(dao)入泡(pao)殼毛胚(pei)中，風干后形(xing)成石膏(gao)毛胚(pei)；4.采用(yong)(yong)電動銑床對石膏(gao)毛胚(pei)和(he)規則(ze)形(xing)狀進(jin)行深(shen)加(jia)工；5.手(shou)工打(da)(da)磨(mo)和(he)手(shou)工添加(jia)部件；6.將(jiang)各個拋光好(hao)的石膏(gao)部件粘合成完(wan)整的石膏(gao)模；7.再放入吸(xi)(xi)塑(su)打(da)(da)版機(ji)吸(xi)(xi)塑(su)成型完(wan)整的樣(yang)品(pin)；8.按成品(pin)尺寸(cun)，手(shou)工切邊(bian)、封(feng)邊(bian)，完(wan)成全(quan)(quan)部打(da)(da)樣(yang)過程(cheng)。如果(guo)有需求(qiu)，印(yin)(yin)刷打(da)(da)樣(yang)部門同時會(hui)將(jiang)吸(xi)(xi)塑(su)樣(yang)品(pin)所用(yong)(yong)的紙卡、不干膠或彩盒一起(qi)制(zhi)作(zuo)，他(ta)們會(hui)借助全(quan)(quan)開的印(yin)(yin)刷數碼(ma)打(da)(da)樣(yang)機(ji)能將(jiang)實(shi)際印(yin)(yin)刷結果(guo)反映出來。

五、制(zhi)作(zuo)(zuo)(zuo)生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)模(mo)(mo)(mo)(mo)具(ju)：樣品被客(ke)戶認可(ke)后(hou)，通常會下一(yi)定數(shu)量的生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)訂單(dan)。生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)調度(du)會根據產(chan)(chan)(chan)(chan)量、吸塑(su)成(cheng)(cheng)(cheng)型(xing)(xing)的復(fu)雜程(cheng)度(du)決定采(cai)(cai)用(yong)(yong)(yong)(yong)哪種模(mo)(mo)(mo)(mo)具(ju)量產(chan)(chan)(chan)(chan)：采(cai)(cai)用(yong)(yong)(yong)(yong)石(shi)膏(gao)(gao)模(mo)(mo)(mo)(mo)生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)，模(mo)(mo)(mo)(mo)具(ju)制(zhi)作(zuo)(zuo)(zuo)過(guo)程(cheng)類似于(yu)吸塑(su)打樣，優點(dian)(dian)在(zai)于(yu)生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)周(zhou)期(qi)(qi)短(duan)，成(cheng)(cheng)(cheng)本(ben)(ben)低，制(zhi)作(zuo)(zuo)(zuo)一(yi)整(zheng)(zheng)版（60X110cm)模(mo)(mo)(mo)(mo)具(ju)只需(xu)一(yi)到(dao)(dao)兩天時(shi)間，不足之處(chu)在(zai)于(yu)吸塑(su)成(cheng)(cheng)(cheng)品表面粗糙，生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)中模(mo)(mo)(mo)(mo)具(ju)容易碎裂(lie)，耐用(yong)(yong)(yong)(yong)性(xing)差(cha)無(wu)法成(cheng)(cheng)(cheng)型(xing)(xing)深(shen)度(du)大、復(fu)雜度(du)高(gao)、片(pian)材(cai)厚(hou)的產(chan)(chan)(chan)(chan)品。采(cai)(cai)用(yong)(yong)(yong)(yong)電鍍(du)(du)(du)銅模(mo)(mo)(mo)(mo)，其工(gong)藝(yi)是(shi)(shi)(shi)(shi)將(jiang)(jiang)打好(hao)樣的">泡殼表面噴(pen)上一(yi)層導電劑，再放(fang)入電解槽內鍍(du)(du)(du)上厚(hou)厚(hou)的銅層，電鍍(du)(du)(du)過(guo)程(cheng)需(xu)要(yao)72小時(shi)，接(jie)著要(yao)對銅模(mo)(mo)(mo)(mo)進行灌(guan)石(shi)膏(gao)(gao)（增加硬(ying)度(du)）、拋光、打氣(qi)眼處(chu)理，采(cai)(cai)用(yong)(yong)(yong)(yong)電鍍(du)(du)(du)銅模(mo)(mo)(mo)(mo)生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)的優點(dian)(dian)是(shi)(shi)(shi)(shi)吸塑(su)制(zhi)品表面光滑，成(cheng)(cheng)(cheng)本(ben)(ben)適中，耐用(yong)(yong)(yong)(yong)性(xing)適中，缺(que)點(dian)(dian)是(shi)(shi)(shi)(shi)模(mo)(mo)(mo)(mo)具(ju)制(zhi)作(zuo)(zuo)(zuo)周(zhou)期(qi)(qi)長，無(wu)法完(wan)成(cheng)(cheng)(cheng)精密吸塑(su)制(zhi)品的生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)。采(cai)(cai)用(yong)(yong)(yong)(yong)吸塑(su)鋁(lv)模(mo)(mo)(mo)(mo)生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)，模(mo)(mo)(mo)(mo)具(ju)制(zhi)作(zuo)(zuo)(zuo)需(xu)要(yao)先(xian)采(cai)(cai)用(yong)(yong)(yong)(yong)電腦設計圖紙，再采(cai)(cai)用(yong)(yong)(yong)(yong)CNC數(shu)控銑(xian)床加工(gong)，優點(dian)(dian)是(shi)(shi)(shi)(shi)制(zhi)作(zuo)(zuo)(zuo)周(zhou)期(qi)(qi)適中，后(hou)期(qi)(qi)模(mo)(mo)(mo)(mo)具(ju)處(chu)理時(shi)間短(duan)（鉆(zhan)氣(qi)眼工(gong)作(zuo)(zuo)(zuo)在(zai)CNC加工(gong)時(shi)完(wan)成(cheng)(cheng)(cheng)），吸塑(su)產(chan)(chan)(chan)(chan)品尺(chi)寸(cun)精度(du)高(gao)，模(mo)(mo)(mo)(mo)具(ju)耐用(yong)(yong)(yong)(yong)性(xing)強，缺(que)點(dian)(dian)是(shi)(shi)(shi)(shi)成(cheng)(cheng)(cheng)本(ben)(ben)高(gao)。由于(yu)全自(zi)動高(gao)速(su)吸塑(su)成(cheng)(cheng)(cheng)型(xing)(xing)機(ji)的成(cheng)(cheng)(cheng)型(xing)(xing)范圍是(shi)(shi)(shi)(shi)66X110cm左右，所以不管是(shi)(shi)(shi)(shi)石(shi)膏(gao)(gao)模(mo)(mo)(mo)(mo)、銅模(mo)(mo)(mo)(mo)還是(shi)(shi)(shi)(shi)鋁(lv)模(mo)(mo)(mo)(mo)，都需(xu)要(yao)將(jiang)(jiang)單(dan)個的模(mo)(mo)(mo)(mo)具(ju)拼在(zai)一(yi)起，達到(dao)(dao)成(cheng)(cheng)(cheng)型(xing)(xing)尺(chi)寸(cun)，我們都稱這(zhe)個過(guo)程(cheng)為拼版，需(xu)要(yao)拼在(zai)打好(hao)氣(qi)孔的鋁(lv)板(ban)或木板(ban)上，拼好(hao)后(hou)的整(zheng)(zheng)版模(mo)(mo)(mo)(mo)具(ju)我們稱之為底模(mo)(mo)(mo)(mo)。對于(yu)吸塑(su)成(cheng)(cheng)(cheng)型(xing)(xing)深(shen)度(du)大的產(chan)(chan)(chan)(chan)品，還需(xu)要(yao)制(zhi)作(zuo)(zuo)(zuo)上模(mo)(mo)(mo)(mo)，在(zai)底模(mo)(mo)(mo)(mo)將(jiang)(jiang)片(pian)材(cai)真空(kong)吸成(cheng)(cheng)(cheng)型(xing)(xing)的同時(shi)，從片(pian)材(cai)上方施加壓(ya)力，將(jiang)(jiang)片(pian)材(cai)均勻地拉(la)伸到(dao)(dao)每一(yi)個部位(wei)，否則(ze)會引(yin)起局部厚(hou)度(du)過(guo)薄。生(sheng)(sheng)(sheng)產(chan)(chan)(chan)(chan)模(mo)(mo)(mo)(mo)具(ju)的整(zheng)(zheng)個制(zhi)作(zuo)(zuo)(zuo)周(zhou)期(qi)(qi)應(ying)為5至7天。

六、吸(xi)(xi)(xi)(xi)塑(su)(su)成(cheng)型(xing)生產：采用(yong)全自(zi)(zi)動高速吸(xi)(xi)(xi)(xi)塑(su)(su)成(cheng)型(xing)機(ji)生產，其基(ji)本原理是(shi)：將(jiang)成(cheng)卷的(de)(de)片(pian)(pian)材(cai)(cai)(cai)拉(la)進電爐(lu)烘箱(xiang)內加熱(re)(re)(re)至(zhi)軟化(hua)(hua)狀態，乘熱(re)(re)(re)再(zai)(zai)拉(la)到吸(xi)(xi)(xi)(xi)塑(su)(su)模(mo)具(ju)(ju)上方，模(mo)具(ju)(ju)上移并抽(chou)真空，將(jiang)軟化(hua)(hua)的(de)(de)片(pian)(pian)材(cai)(cai)(cai)吸(xi)(xi)(xi)(xi)附到模(mo)具(ju)(ju)表面，同時(shi)(shi)將(jiang)冷卻(que)水以(yi)霧狀噴于(yu)成(cheng)型(xing)片(pian)(pian)材(cai)(cai)(cai)表面，使其硬化(hua)(hua)，成(cheng)型(xing)的(de)(de)片(pian)(pian)材(cai)(cai)(cai)再(zai)(zai)自(zi)(zi)動被拉(la)至(zhi)貯料箱(xiang)，氣動裁刀將(jiang)成(cheng)型(xing)與(yu)未成(cheng)型(xing)片(pian)(pian)材(cai)(cai)(cai)分離(li)，從而完成(cheng)全部過程。吸(xi)(xi)(xi)(xi)塑(su)(su)產品(pin)出(chu)現的(de)(de)主要質量問題大多在此過程發生：1.吸(xi)(xi)(xi)(xi)塑(su)(su)不到位，是(shi)指(zhi)(zhi)形狀變形，沒(mei)有吸(xi)(xi)(xi)(xi)塑(su)(su)成(cheng)與(yu)模(mo)具(ju)(ju)相(xiang)同形狀的(de)(de)產品(pin)；2.吸(xi)(xi)(xi)(xi)塑(su)(su)過度，是(shi)指(zhi)(zhi)產品(pin)過薄(bo)；3.拉(la)線，是(shi)指(zhi)(zhi)成(cheng)型(xing)產品(pin)上出(chu)現不應有的(de)(de)線痕；4.厚(hou)薄(bo)不均。這些問題都(dou)需要在上好(hao)模(mo)具(ju)(ju)后，調試到位，包括：片(pian)(pian)材(cai)(cai)(cai)前進的(de)(de)時(shi)(shi)間(jian)(jian)、加熱(re)(re)(re)的(de)(de)溫度和(he)(he)時(shi)(shi)間(jian)(jian)、抽(chou)真空的(de)(de)強度和(he)(he)時(shi)(shi)間(jian)(jian)、上模(mo)下落(luo)的(de)(de)位置、時(shi)(shi)間(jian)(jian)和(he)(he)深(shen)度、拼版中(zhong)模(mo)具(ju)(ju)的(de)(de)擺放(fang)位置、模(mo)具(ju)(ju)間(jian)(jian)是(shi)否加附件等(deng)等(deng)。

七、沖床(chuang)加(jia)工：吸塑成型的(de)大版面產品(pin)必須(xu)經過沖床(chuang)，用(yong)一(yi)塊刀版分(fen)割成為單(dan)(dan)(dan)一(yi)的(de)產品(pin)。其原理是在(zai)沖床(chuang)的(de)底臺上有一(yi)大張塑料(liao)砧(zhen)(zhen)板(ban)，將大版面成型產品(pin)放在(zai)砧(zhen)(zhen)板(ban)上，并(bing)把(ba)事先(xian)做好(hao)的(de)刀模(mo)卡在(zai)單(dan)(dan)(dan)一(yi)產品(pin)上，通過沖床(chuang)的(de)上下運動(dong)，裁斷(duan)出單(dan)(dan)(dan)一(yi)的(de)成品(pin),但這種(zhong)裁斷(duan)方式的(de)不(bu)足之處在(zai)于砧(zhen)(zhen)板(ban)和刀模(mo)比較容易損(sun)壞,從而(er)造成切(qie)邊不(bu)光滑,有毛邊,對(dui)于質量要求高的(de)泡殼,需要用(yong)冷沖模(mo)(一(yi)個公模(mo),一(yi)個母(mu)模(mo))和冷沖床(chuang)加(jia)工。