Canadian Finishing and Coatings Manufacturing: Nov/Dec 2022 - 32

PLATING AND ANODIZING: ELECTROPLATING MASKING SOLUTION
on the material and the fact that they can reuse it is a huge selling
feature. "
Caplugs quickly designed and provided prototypes, which
Autotek tested and suggested modifications to the cap, such as
adding the grip-like piece on the angled edge.
" I asked them to add that grip to provide more structure and
keep the integrity of that right angle, " says Edwards. " You can see
on the inside it's hollowed out or a void in the middle of the cap to
allow it to go over that 90-degree bend. I didn't want it to be super
tight or to keep the solution out, I just didn't want it to plate. It's
inevitable that you will get solution in the cap, so we do have to be
careful when removing it to not affect the plated surface. "
Once the modifications were completed, Autotek put the
prototypes into production for about five months before ordering
3,000 of each cap. Currently it has 1,800 caps in production and
they've run just under 30,000 parts, which equates to 17 cycles
the caps have been used in so far. As the product is processed, the
caps are at various stages such as masked and unmasked.
" The program is for 2,000 left side and 2,000 right side per
week. We were planning on batch running once or twice a week.
But of course, automotive is all over the place-for months we
won't see any orders and then all of a sudden, they'll need 8,000, "
says Edwards. " The caps provide more flexibility and it's easier to
process with a quicker turnaround. "
While the initial cost of the custom NBR cap is more expensive
per part, the savings is inevitable as the caps are reused. Edwards
says that the direct labour cost for the liquid masking was
about 4.5 times more expensive compared to using the NBR
cap. However, the direct material cost of the liquid mask was
significantly lower as the custom masking from Caplugs required
the more expensive NBR material as well as the investment in
the tooling to manufacture. But, with the part reusability of the
NBR solution, Edwards' per-piece cost continues to drop as the
part is reused in the finishing cycle.
" To date, the masks have been used 17 times on about 30,000
pieces, " says Edwards. " Our masking cost per piece was $1.22
and is now $0.46 and will continue to decrease until the masks
need to be replaced. "
Edwards admits that the company typically will look through
a masking catalogue for solutions and this was the first time
buying a custom solution. " All in all, as difficult as masking can be
and as difficult this project has been, having this custom solution
has been a good move and a positive move. "
With 17 facilities worldwide and a large team of in-field sales
managers across the globe, Caplugs provides the personalized
service, range of capabilities, wide variety of catalogue parts,
manufacturing expertise and scalable infrastructure to be a
trusted partner for many industries. This includes product
protection for automotive, aerospace, medical, packaging and
other markets, as well as solutions for customers' coating and
masking needs.
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Canadian Finishing and Coatings Manufacturing: Nov/Dec 2022

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