Tuesday, May 18, 2010

Worth the Wait

Sorry I haven't posted in awhile! Things have been quite busy at Crown Premiums lately. We are excited about the programs that we are working on together with our customers and can't wait to share them with you. If your company needs assistance with putting together a successful promotional program, please contact us at info@crownpremiums.com. We do all the work, and you collect the cash while also having a strong, unique promotion.

I am reviewing old newsletters and came across a great article from David Brody, our VP of Operations. Enjoy!

A new die cast replica takes one year to develop from the prototype stage to a delivered product. Why does it take so long?

After we've decided on a new item, gathered all specifications and worked out basic engineering, our China factory is ready to produce a prototype. The prototype is a pattern model that is precisely carved by hand. If the replica has any electronic or integrated chip (known as I.C.) function, that will be part of the prototype. Creation and approval of the prototype, including modifications, takes about two months.

After the prototype is approved and engineering drawings are completed, we start to fabricate the molds. The molds are made of heavy-gauge carbon steel and include die cast (which makes bon steel and include die cast (which make the zinc metal parts) and injection (which makes the plastic parts). Molds could also include metal stamping and dies for extrusions. Molds may produce more tan one part, this is called a "family" mold. For example, all plastic parts that will be chromed plated would be included in one mold. The carving process to fabricate the molds is a combination of hand work and computer automation and takes four months. The factory then tests the molds and assembles the replica samples to check part fit and function. Another month will be spent making final modifications, such as improving the overall fit of all parts and function of moving parts. Included in this final process is a polishing of the molds, which ensures a smooth surface for painting. Much of this work is done by hand.

Once the molds have been completed, we start the three-month production process. The first step is the molding, which for some of our items (such as the pedal cars) can involve over 150 different parts. After molding, the die cast parts go through a multi-stage deburring and polishing. Much of this is done by hand. The plastic parts are molded and the n separated into category by finish, which includes those to be painted, chrome plated, or not finished.

To be continued. . .

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