Author: hqt

Packaging machine fabrication components endure unbelievable wear and tear, and packaging machine manufacturers know this all too well. At Essai, Inc., we understand that when a business contacts us with a broken part or piece of packaging equipment, time is money. We have the in-house experience to take your packaging needs and ideas from the concept and design phase all the way to their full fabrication and installation.

To sell successfully, today’s consumer goods rely heavily on the appropriate packaging. It’s not just about sealing in quality and freshness or containing complex and irregularly sized products. It's also about how these goods can best be transported and displayed. Naturally, both material and labor costs are important factors when companies decide on the method and style for packaging their consumer goods.

Whether you want to repair existing packaging equipment and only damaged parts. We still have to decide how to integrate a piece of packaging equipment into the production line. You should all work with packaging machine manufacturers with proprietary technology to provide the highest quality and maximum value.

That’s why working with Essai is the smartest choice you can make. We have a 72, 000-square-foot, world-class facility with state-of-the-art equipment as well as a one-decades-long list of satisfied clients.

Your customer base won’t wait if your distribution goes down because of faulty packaging equipment. So how do you get the results you’re looking for consistently and within your budget? The answer is simple: Work exclusively with a packaging machine manufacturer that’s certified in everything from reverse-engineering to computer numeric control (CNC) machining.

CNC Packaging Machine Fabrication Capabilities

At Essai, we’ve been refining our CNC machining capabilities for well over 10 years. In addition, with full reverse-engineering services from our best-in-class, highly trained engineers and machinists. We can extract all the design information necessary to produce repeatable replacement parts for any broken piece of equipment you have. As well as generate a CAD model for future reference.

Whatever your packaging needs are — from shrink-wrap packaging and bundling to clamshell packaging and pallet containment — you want reliable service on everything from getting a quote to agreeing on an installation and testing timeline. Once again, this is why working with Essai can benefit your business and help protect your bottom line.

Certified Quality and Craftsmanship

As a member of the Manufacturers’ Association, with a fully certified quality management system in accordance with AS9100D and ISO 9001:2015. Essai has the experience and track record you want in a one-stop packaging machine manufacturer. You can rest assured that all of our equipment manufacturing, assembly, repair, and technical support follow the strictest quality and industry standards.

In addition to filling your most complex and custom orders, we’re dedicated to delivering value and top-notch customer service. Plus, you’ll have the confidence that only comes from employing a certified ISO 9001 and AS9100 American small business with an accredited A+ Better Business Bureau rating.

Get to the market on time. Contact us now to learn what Essai-built machining services are all about.

The materials and manufacturing technologies of Aerospace CNC Machining parts are developing toward high temperature, lightweight, compounding, integration, high efficiency, and low cost. The manufacturing technology of complex structural components such as aircraft casings and integral blade disks of aviation engines is constantly improving. Manufacturing technology has evolved from advanced manufacturing to high-end manufacturing. Aviation complex structural parts processing technology involves CNC machine tools, advanced tools, efficient programming, CNC machining simulation and cutting process and parameter optimization.

Processing of typical complex structural Aerospace CNC Machining parts

Aerospace CNC Machining parts use a large number of difficult-to-machine materials and composite materials such as titanium alloys and high-temperature alloys, and their machinability is extremely poor. The parts of the casing and the whole leaf disc are complex, and it is easy to produce machining deformation. The dimensional accuracy and technical requirements are difficult to guarantee.

The machining of the integral leaf disc type is a typical five-axis CNC milling. The airflow passage between adjacent blades is narrow, and the surface between the blades is prone to interference during processing, which has extremely high requirements for the tool path. Because of the easy interference. It is necessary to test the accuracy of the machining program by simulation before actual machining.

Whole leaf disc processing simulation steps:

1. In the VERICUT environment, call the constructed five-axis machining center model. Call machine files, CNC control files, and tool magazine files.
2. Introduce the blank STL model file of the whole leaf disc into the component tree and set the workpiece coordinate system.
3. Transfer to the NC program and define the tool list.
4. Check the correctness of the NC program. Set the recognition color such as collision, overtravel, and interference to check the interference between the machine tool, the tool, and the fixture.
5. Impeller simulation results analysis, check the parts for undercut, overcut, confirm whether the program can be used.

The machining of complex structural parts of aero-engines relies on innovations in process methods. Its manufacturing level directly determines the performance of the aero engine.

Essai provides rapid prototyping service, Aerospace 3D Printing, Aerospace injection molding, Aerospace CNC Machining, low-volume, on-demand. No MOQ. Fast delivery free design.

Food processing machining equipment manufacturers face some of the highest standards when it comes to quality control and sanitation concerns. After all, more and more Americans are consuming ready-to-eat and prepared foods. Additionally, there’s a growing number of consumers with food-based allergens. As a result, public health is a top priority for those directly involved in the food industry as well as those whose job it is to manufacture and service the industry’s food processing equipment.

While a majority of consumers may not give it much thought, the food industry and the standards that govern its operations have undergone dramatic changes over the past decades. This is in large part due to the fact that our knowledge of foodborne contaminants, pathogens and allergens has been greatly enhanced by scientific research and reporting.

These concerns, as they apply to food processing equipment standards, culminated in the Food and Drug Administration convening a working group through the Center for Food Safety and Applied Nutrition. This working group is tasked with reviewing and updating the Current Good Manufacturing Practice (CGMP). Among other things, the CGMP calls for strict controls, training, and record-keeping so that processes such as sanitation procedures and quality checks include all food processing equipment and surfaces that come into contact with any foods.

For food companies, this means their processing equipment must be fully compliant with the FDA’s CGMP regulations. For this reason, they need equipment and parts manufacturers. They informed about those regulations and can deliver products that are fully compliant. That’s why Essai, Inc. is such a trusted leader in the manufacturing and machining of food processing equipment and parts.

CNC Machining for the Food Industry

From industrial mixers to microbe-resistant conveyors. The food industry employs one of the widest varieties of processing equipment used in large-scale production enterprises. When even one part of a production line goes down because of equipment failure. It can spell disaster for a company’s bottom line.

Fortunately, for more than 30 years. Essai has been refining its use of computer numeric control (CNC) machining to supply the food industry with a fast, safe and cost-effective service. It's not uncommon for one of our clients to come to us with nothing more than a broken part. Then we reverse-engineer to create a replacement part. In addition, we’re skilled at generating CAD models. So even if the part is from a custom piece of food processing equipment, ordering future replacement parts is fast, easy and affordable.

Design and Manufacturing of the Highest Quality

Whether it’s the speed and precision supplied by our five-axis machining and milling. Or our extensive experience using a wide range of materials and alloys associated with food processing equipment. We provide you with the results you’re looking for in a turnaround time that keeps you in business.

For the highest quality, value, and service, Essai is the food industry’s trusted choice. Contact us today to learn more about what we can do for your business.

Consumer electronics products refer to audio and video products for personal and home-related radio and television, and electronics molds include TV molds, DVD player (VCD, SVCD, DVD) molds, video recorder molds, camcorder molds, radio molds, Recorder mold, in some developed countries, telephones, personal computers, home office equipment, home electronics medical equipment and automotive electronics are also included in consumer electronics. With the development of technology and the emergence of new products and applications, digital cameras, mobile phones, PDAs and other products have also become emerging consumer CNC electronic products.

The metal structural components of consumer electronics products refer to the protection and support of high dimensional accuracy, high surface quality stars and high-performance hardware components in consumer electronics products. A wide range of products is an important part of consumer electronics. Metal structural components of consumer electronics are important components of consumer electronics. Their design and manufacturing account for about half of the mobile consumer electronics product development cycle, and their cost accounts for about 15% of the cost of mobile consumer electronics materials.

According to the raw materials, the structural part molds of consumer electronics are mainly divided into ABS engineering plastic part molds, polycarbonate part molds, metal part molds, etc. Among them, metal parts mainly include magnesium alloy part molds and stainless steel part molds. Steel parts. For a long time, ABS engineering plastics are the main materials for structural components of consumer electronics, but plastic structural components usually have the disadvantage of poor durability. Metal structural parts are fascinated by consumers for their thin materials, high-strength support, good texture, and fast heat dissipation. In the past two years, it has been increasingly used in high-end products by consumer electronics manufacturers.

Consumer CNC Electronic Development

With the development of thin and light consumer electronics, stylish and distinctive components. Metal structural parts have the advantages of high strength, good toughness, fast heat dissipation, lightweight and good texture, etc., and have obtained obvious advantages in the market. Mainstream development trends. With the development of new processing technologies, processes and consumer acceptance, the application of new material structural components will also occupy a place in the future.

The rapid development of the global consumer electronics market has provided a broad market space for the development of the metal structure mold industry for consumer electronics products, and the industry has expanded rapidly. At the same time, the trend of diversification, personalization, and thin and light appearance of smart terminals for consumer electronics products, as well as the structural complexity caused by the rise of wearable devices, has continued to improve the technological level, innovation ability and production process of smartphones. Metal structure mold industry. Consumer electronics products' demand for metal structural parts molds is growing rapidly.

Consumer CNC Electronic Products Rapid Development

With the improvement of people's consumption level, the demand for consumer CNC electronic products is expanding, product upgrades are accelerating, the scale of the consumer electronics market is constantly growing, and the mold-related industries are also rapidly developing. Data show that driven by the rapid growth of smartphones, tablets, PCs and other terminal devices, the global consumer electronics market reached nearly 790 billion euros in 2015, an increase of 15% over the previous year.

The scale of China's electronic information industry has continued to expand, and a relatively complete manufacturing system and industrial supporting infrastructure have been formed. According to the National Bureau of Statistics, China's electronics and information industry sales revenue reached 15.4 trillion yuan in 2015, an increase of more than 10.4%. China's electronic information manufacturing industry above designated size achieved a sales output value of 113,294.60 billion yuan, an increase of 9.0%. The output value of major products such as mobile phones and integrated circuits reached 1.81 billion and 108.72 billion, respectively, a year-on-year increase of 7.8% and 7.1%. The output of consumer electronics products such as mobile phones, personal computers, and tablet computers accounted for more than 50% of global output, ranking first in the world.

Tips on two shot peening die

Multi-color multi-material injection molding refers to combining several plastics into one multi-functional part in one manufacturing process or one production unit. This technology uses multiple materials for injection molding and combines the characteristics of different materials during assembly or other suitable bonding methods to improve the functionality and aesthetics of the product, significantly save costs and provide new designs possibility.

Necessary conditions for two-color injection

The mating material used for two-color injection molding must meet two basic compatibility conditions, namely adhesive compatibility and process compatibility.

Two-color injection molding also sets new requirements for injection molding equipment. For the injection unit, parallel, horizontal and vertical L-shaped and Y-shaped single-cylinder injection structures can be used. For mixing nozzles, special nozzles such as patterns, waves, flow marks, gradients, and intermediate layers can be selected. In terms of clamping, you can choose the standard type, vertical rotation type, horizontal rotation type, rotation axis type, robot rotation type. In terms of feed, in addition to standard hydraulic motor drives, ESD (electric screw drive) charging structures can also be used. For oil circuits, high-speed injection and closed-circuit designs of ACC accumulators are available.

One of the key factors for two-color injection is the variability of computer-controlled programs. Because even for the same type of multi-color product, if you use different mold designs, you must match different electronic control programs. After purchasing a multi-color injection molding machine, if you encounter a new mold design, an excellent multi-color injection molding machine supplier can quickly upgrade existing equipment to meet injection requirements.

New developments in technology

Combined with the observation of two-color injection molding in recent years, in addition to traditional multi-color products (such as automotive lamp molds, air-conditioning panel molds, and TV frame molds), European and American manufacturers have upgraded to several basic molding technologies. Multicolor injection molding field. "Combination" demos, such as two-color molding and in-mold labeling (IML), two-color molding and in-mold assembly (IMA), two-color molding and stack mold (Stack Mold), two Multi-color moldings plus IML plus IMA plus layer mold can complete two-color molding and sandwich injection on the injection molding machine. Therefore, multi-color injection molding technology has attracted more and more attention, and it can not only present multi-color technology.

Multi-color molding technology for headlights

With the development of the national economy, the automobile industry has become our pillar industry. The rapid development of the current automotive industry has put increasing demands on automotive lighting.

The quality of automotive lighting is very important for driving safety, so regulations in various countries around the world have strict requirements for automotive lighting. The design of luminaires should not only meet regulatory safety requirements but also meet other requirements. For example, the appearance should be integrated with the appearance of the entire vehicle, be beautiful and practical, and meet aerodynamic requirements to make the driver and passengers feel comfortable and convenient. Therefore, with the development of the automotive industry, the design technology of lamps is also changing.

Material and process characteristics of the lamp

The lamp usually consists of a base and a lamp housing. The material of the lamp cap is usually a thermosetting material-BMC (bump molding compound). The lamp shell can be made of PMMA, PP, abs, etc., usually two or three colors. In the production process of two-color lamps, special attention should be paid to the injection port of the two-color injection molding machine. The center distance between the two screws should correspond to the center distance of the two injection molds. There are other important points:

Factors Influencing Lamp Stability

1. Two-color injection control unit response: too many switching points, noise interference, unstable command output, and unstable temperature.
2. The noise of hydraulic system: unstable excitation, valve positioning quality, hysteresis, tubing damping changes.
3. Differences in mechanical systems: internal leaks in oil seals, damping, friction differences, screw check valve positioning, anti-reverse effect
4. Uneven plasticization: differences in plasticized products.
5. Mold temperature control.

Countermeasures for car luminescence

1. Carbonization reduces injection pressure, multi-stage deceleration injection, and mold vacuum.
2. The silver pattern completely dries the plastic particles, increasing the back pressure, reducing the melting temperature, and reducing the rate of fire.
3. Bubbles-increase the backpressure, reduce the melting temperature, use a dehumidifier dryer to increase the size of the gate or runner.
4. Bonding line-increase melt temperature, increase filling speed and increase exhaust and mold temperatures.
5. Gross profit-increase clamping force, reduce filling pressure and lower melting temperature.
6. Shrink uniform thickness design, increase pressure and time, and replace the check valve.

Frequently Asked Questions about Headlamp Plastic Tube Kit Design

1. The screws are not idling.
2. The torque required for the screw is too large to rotate.
3. The plastic is not completely melted.
4. Screw measurement is unstable.
5. Uneven mixing of plastic.
6. Low-temperature plastics tend to rise in temperature.
7. There are air bubbles in the molded product.
8. Molded products are easy to vomit and turn yellow.
9. The screws are prone to corrosion, wear and short life.

Main design points of screw material tube

Plastic screw material tube group is the core component of an injection molding machine, which is responsible for the function of conveying, melting, mixing and metering plastic raw materials. Therefore, the plasticized screw is closely related to the quality of the molded product.

The main purposes of modified plasticized screws are:

1. Improve shear mixing.
2. Stir well.
3. Improve plasticizing ability.
4. Make sure the melt temperature is uniform.

Focus on design screws for taillights

1. L / D ratio: 21-23.
2. The surface roughness of two-color injection molding must be very smooth to avoid accumulation.
3. Improve the corrosion resistance of the coating.
4. Two-color injection compression ratio: 2: 3; feed section: about 50%; compression section: about 30%; metering section: about 20%.

To make a set of two molds, it can be said that the design accounts for 50%. According to industry insiders, the range of requirements for the mold design process is very wide. In addition to requiring the design engineer to have extensive knowledge of mold theory and experience, it is also important to review and think before designing:

Proofreading review-Before completing the design of two injection molds, a proofreading review must be conducted with the customer and related personnel to comprehensively check the overall structure of the drawing structure, processing feasibility and omissions, solicit customer comments and avoid design errors, etc. Molds, used or even scrapped.

CNC medical machining device components is always a difficult process. Because the components for medical devices are usually complex and require high precision. Essai is a professional precision machining supplier with the capacity to manufacture complex and high accurate components for medical devices OEMs. Essai machining medical components from one prototype to thousands. And we pay high attention to each project to ensure we deliver qualified components to our customers.

The components we machining for the CNC medical machining industry:

• Surgical instruments components
• Orthopedic medical devices components
• Dental components
• Ventilator components
• Fittings

Essai is state-of-the-art and uses advanced machines for precision medical machining. We always optimize our machines for high precision machining.

The services we provide to the CNC medical machining industry include:

• Swiss machining
• Screw machining
• CNC machining, CNC milling, and CNC turning
• Precision machining and custom machining
• Complex machining
• Prototype machining

Our experienced engineers and quality control team monitor the entire medical device machining process well and adheres to the strict in-house quality policies. If you need your medical device components to be machined, welcome to contact us for a quick quotation. Essai will be your good partner for your precision medical machining!

Globally, one of the industries that rely most heavily on precision manufacturing of equipment is the energy sector. From oil and gas equipment manufacturing to machining nuclear components. We know from experience what’s on the line when one of our energy clients contacts us with an order. Of course, time is of the essence. Since even a minor shutdown can mean huge costs for a CNC energy equipment company. Additionally, worker safety and field use are taken into consideration. Every component we deliver must meet the strictest durability and quality guidelines.

In addition to our experience in the oil, gas, electrical and nuclear sectors. We're also highly skilled at producing renewable energy components for solar and wind energy. That’s why, whether you’re looking for a precision-made valve on a piece of oil extraction equipment or a crucial component for use in a wind turbine, Essai, Inc. has the in-house expertise and world-class facility to meet your needs, budget and deadline.

CNC Machining Importance

The risk of fire in the oil and gas industry, the wear and tear on wind turbines, the control and safety concerns in the nuclear sector — these are just some of the factors that contribute to the unique challenges faced by the energy sector on a daily basis. It’s for all these reasons and more that computer numeric control (CNC) machining is such a critical element in the manufacturing and machining of energy sector equipment. Regardless of whether it’s a safety valve for use in a fire suppression assembly or a corrosion-resistant part for a marine-based wind turbine, you can rely on our more than 10 years of experience in CNC machining energy industry parts and components.

Since the late 1960s, the automated process of CNC has been used to produce ever more precise parts. Combine that with our ongoing experience working with the latest alloys and raw materials, and you begin to see why our CNC machining of oil and gas, electrical, nuclear, wind turbine and solar energy equipment has become the industry hallmark of excellence.

Full-Service Machining Solutions Across All Energy Sectors

From custom machine building and reverse-engineering to 5-axis machining and milling. Our 72,000-square-foot facility in Ephrata, PA, is equipped to meet all your company’s equipment and project needs. As a certified ISO 9001 and AS9100 small business with top-rated customer service representatives and fully qualified engineers and machinists. Essai is your one-stop machine shop.

In addition to the services previously mentioned. We're fully experienced in working with all metals and alloys, have complete in-house inspection capabilities and supply expedited delivery services and job tracking on all orders — regardless of the size of the project.

If your business prides itself on being a reliable part of the energy sector. The smartest decision you can make is to let Essai be your number one choice for all your machining needs. We know our ongoing success is fully reliant on meeting the expectations of our clients. Contact us now to learn more about how our precision and efficiency mean value to you.

CNC (computer numerical control) machine light uses multiple tools, such as drills, saws, and many others in a single cell to automate the manufacturing process and make it more efficient. These areas require heavy-duty washdown treatments after use and need extremely bright lighting for inspection purposes. Bright, visible LED light allows operators to inspect CNC areas to ensure machines are working properly to produce parts faster and more efficiently.

Determining a lighting solution for the CNC machine is simple with Banner’s LED heavy-duty machine light, which provides enhanced chemical and thermal resistance in tough environments. The super-bright lamp has oil resistance of IP68, IP68g and IP69K, chemical resistance and water resistance. They make it an ideal choice for many industrial lighting applications, including CNC flushing environments. The heavy-duty light stands up in the harshest environments. So operators can focus on the task at hand rather than spending time repairing or replacing lights or parts.

The LED technology of Essai ’s WLC60 LED machine light ensures years of operation without maintenance. This reduces costs, improves the visibility of human eye inspections, and improves product quality and productivity. LED lights easily replace fluorescents for improved work station operation and reduced replacement, repair and overall energy costs.

The light has a durable polycarbonate window or borosilicate glass option available for enhanced resistance to oils, chemicals, and water. The light is simple to install with a variety of mounting options to suit any machine or environment. Mounting options include magnetic mount, daisy-chain power and rear or side connectors.