At Carlon Plastics we undertake a range of manufacturing processes in the production of our plastic products.
- CNC Routing
- Drape Forming
- Line Bending
- Vacuum Forming
- Laser Cutting
- Bonding & UV Bonding
- Polishing Diamond/Flame/Buff
With computerised routing, we are able to produce almost any cut shape from an extensive range of plastics. Parts are machined to very fine tolerances and finished to a high standard. From CAD drawings, components can be produced with consistent repeatability.
This process is for producing large curves in flat panels of plastic in thicknesses up to 25mm, particularly acrylic. Oven heated material is draped over a male mould and left to cool in order to achieve the desired shape. A slightly more sophisticated technique uses a male-female mould, sandwiching the plastic sheet. Tooling is relatively cheap and therefore cost effective for medium to low volume production.
Thermoplastic of lengths up to 3m can be bent using a strip heater. Single or multiple bends are produced very efficiently by locally heating the plastic. Once heated, it can be folded to the required angle and radius by clamping until cool into a simple jig. Large, as well as tight radii are achievable with this process. We also offer cold bending facilities for Polycarbonate if required.
Vacuum Forming is a process where flat sheet is transformed into 3D components. Material is heated whilst being clamped in a frame. When soft, it is stretched over a mould then sucked down tightly with a vacuum. Once cooled, the newly formed shape is ready for finishing, usually involving trimming excess material and other post ops such as holes, slots and decoration.
Laser Cutting is at the forefront of profiling technology for plastics today. Accurate shapes are able to be cut to the highest of quality, leaving a polished edge which requires no secondary operation to give a finished component. Logos can be laser etched and engraved for that finishing touch.
Bonding & UV Bonding
We can bond a large number of plastics either by solvent welding, 2 part adhesives or UV bonding. For most applications, a solvent weld is quite adequate but where something much stronger is required, 2 part adhesives are recommended, especially for acrylic aquariums, water features and tanks. This, together with UV Bonding will give an optically clear joint, free from bubbles. UV Bonding is the gluing process used when a premium joint is paramount. In the main, it is used for high end applications e.g. Architectural Display Cases, Museum Covers, Lecterns and Furniture.
Diamond Polishing produces a stress free professional finish on straight edges up to 40mm thick. With the removal of 0.5mm of material by the cutter, this high precision polishing delivers a perfect smooth and clear edge every time.
Perfect for rapidly transforming unfinished edges into edges that are smooth, clear and glass-like. Generally, this is used on parts with non-uniform edges.
This process is carried out by hand using a buffing wheel and polishing compound to produce a highly-polished finish. Ideal for use on thicker materials and also for removing blemishes and scratches.