Prototyping

If the part were to cover one or two surfaces, the engineers at the plant would draw something up and send the specifications to our office. We would then cut the parts individually to their specifications for testing in order to create the tool that will cut the parts by rotary or flatbed cutter.

Multiple surfaces

When the die cut has to cover multiple surfaces and be operator friendly, the design gets very complicated. We have had the best results when the part is actually shipped to Budnick Converting and we have at least a day to work on it. We then cut several test pieces and Next Day air to the customer who can try it on the assembly line.

On-Site Prototyping

Our customers also realize a benefit in having us bring the portable plotter to their site in order to work with their operators on the assembly line. This interaction allows the operators to assist in the creation of the die cut and their information and knowledge is invaluable to getting the die cuts perfect. This results in real time prototypes for your application.

User input is key because it allows us to add dry edge tabs to facilitate placing the part in awkward trenches, or perforated parts that tear off when the part is in place, or liners that are scored so that they can be taken off easier and quicker. Some liners are left in place and some tabs are solely for the removal of the die cut after the painting process. The operators always have lots to say about the application of the part; after all, they do the same application and removal processes consistently all day. They know that part and where they get hung up. Many times changing a curve on a die cut makes it harder or easier for the operator to put the die cut on the part. We might move the curve of a corner where they are having problems, drape the rest of the part and send it down the assembly line to the paint stations to see the effect it has on the part.

Why Should We Contact Budnick About Prototyping?

The initial concern that draws us to visit customer sites is the amount of rejections in their production or finishing process. The die cut used in the paint masking process is usually performing an admirable job except some very minute paint spots. In the automotive industry, for instance, a pin head size drop of paint is unacceptable.

Using a computer generated drawing on a laptop and a printer with a blade instead of a pen, vinyl is fed through the printer just like paper and the blade cuts where the computer generated drawing tells it to.

Once on the assembly line, we cut the original vinyl die cut to match it with the parts our customers have been receiving. That way, we can watch them put on the part. This is important as some parts must be put on from left to right only, or applied from top to bottom. Certain die cuts can be used on both sides of the part, and some parts have a left and a right side that require opposite cuts. Some parts have to be on rolls and some have to be on sheets to fit in the shelf of the work station. By working on the assembly line we can pin point a host of details that might affect whether the part ends up as a reject or not.

We understand that every little bit counts when it comes to the speed of the operator. We have laid out parts on a roll so that the operator can pick it up and apply it without changing hands or turning the part. Even scoring the liner so that it comes off with the left hand where the garbage can is kept, saves a step or two. A lot of the time quotas are high and time is short. We try to accommodate every single step of the process and our customers appreciate it immensely.

To find out more regarding Budnick’s prototyping services, feel free to contact us today. We’re listening.