FAQ
ASH Plastics Ltd was established in 1982 and has been serving the acrylic industry now for over 40 years.
FLAME POLISHING
Flame polishing is a polishing method used on both glass and thermoplastics. Acrylic is a thermoplastic and can be very successfully flame polished. Flame polishing is a commonly used method of polishing acrylic, for domestic, commercial and industrial applications. Flame polishing is an efficient process, which produces a clear finish, perfect for professional displays and retail stands.
When looking to polish acrylic, it is important that the surface is first sanded and cleaned to remove any surface imperfections or debris. Acrylic polishing can be achieved in several ways – including flame polishing, diamond polishing, and mop polishing. Flame polishing uses a concentrated flame, held a few inches away from the acrylic, to melt it; the melted acrylic then sets as a perfectly transparent surface.
Acrylic edge finishing applies the same methods as polishing to improve the appearance of the acrylic edges. This likewise includes flame polishing, running a hot flame along the edge of the acrylic to clean the material and improve its transparency.
Simple answer, no! A polycarbonate is a thermoplastic which contains carbonate groups in its chemical composition. It is often a competing material to acrylic and is used for similar applications. Like acrylic, polycarbonate surfaces can be polished to remove any scratches, discolouration, or dullness in the material. It can be polished through several methods, including buffing and sanding, vapour polishing, and chemical polishing; however, you should not flame polish polycarbonate.
PET-G is a thermoplastic polyester, often used as an alternative to acrylic or polycarbonate. PET-G is much more durable than acrylic, however, will need polishing to remove any damage it does receive. Polishing PET-G can be achieved through first sanding the edges with a circular saw, and polishing using a polishing paste and polishing disc. It can also be flame polished, resulting in a transparent and smooth material surface.
Whilst acrylic polishing can be undertaken manually, an acrylic flame polishing machine can be used to speed up the process, increase accuracy, and reduce labour. The flame polishing machine produces an oxygen and hydrogen mixture, which passes through butanone to produce an intense flame, used to melt the acrylic.
MOP POLISHING
When looking to polish acrylic, it is important that the surface is first sanded and cleaned to remove any surface imperfections or debris. Acrylic polishing can be achieved in several ways – including flame polishing, diamond polishing, and mop polishing. Mop polishing uses an abrasive soap or paste, and several polishing discs of varying rigidities to remove the surface material; a drilling machine may also be used to achieve this. Similarly, diamond polishing uses rotating diamonds to remove the surface of the acrylic.
Plexiglass is a brand name for acrylic; this material is prone to scratches and its electrostatic charge means it can easily attract dust and debris, clouding the usually clear plastic sheet. How to clean cloudy Plexiglass is relatively simple; it can be cleaned with a number of substances, one of the most effective being simple warm, soapy water and a non-abrasive cloth. Ammonia-based products, such as glass cleaners, and paper towels, should not be used whilst cleaning acrylic plexiglass, as they can damage the material. Further polishing may be required to buff the material and restore transparency.
PET-G is a thermoplastic polyester, often used as an alternative to acrylic or polycarbonate. It is much more durable than acrylic, however, it will need polishing to remove any damage it does receive. Polishing PET-G can be achieved through first sanding the edges with a circular saw, and polishing using a polishing paste and polishing disc. PET-G can also be flame polished, resulting in a transparent and smooth material surface.
Acrylic mop polishing is an alternate method of cleaning and improving the surface condition and transparency in acrylic material. Mop polishing utilises different grades of mops or cloths which travel along the material, and an abrasive soap, to remove surface material.
DIAMOND POLISHING
Acrylic can be polished using diamond polishing. During acrylic diamond polishing, rotating diamonds travel along straight edges of the acrylic; this produces a clear acrylic sheet. Diamond polishing is not compatible with curved edges, however, so flame polishing may be necessary on such surfaces.
A diamond-tipped wheel rotates at high speed gently smoothing out the acrylic material leaving a glossy and bright finish.
The most common type of plastic material to be diamond polished is acrylic. But you can also use this technique with PET-G, Polycarbonate and ABS. It is especially useful for use with PET-G and Polycarbonate as they are both thermoplastics and they do not react very well to flame polishing.
No. Diamond polishing is an ideal way to produce a high-quality finish on flat/straight surfaces, but it cannot be used on curved surfaces. Where a curved surface requires polishing it is usually flamed.
DOME BLOWING
Dome blowing is a particular process that uses heat to expand materials and create a dome-shaped finish. The height and size of the dome depend on the requirements of the project in question.
Before being loaded into a dome-blowing machine, heat is delivered to a piece of material until it reaches a certain temperature. At this point, the material softens and then is loaded into the blowing machine where it’s clamped into place. At this point, air pressure is applied to the underside of the material. It is then blown up and out. This creates a uniform dome shape that can expand to the desired height and size. Once cooled, it can be unclamped and is ready to be used immediately.
There are a wide variety of products that can be made this way. For example, medical supplies can benefit from hollow containers used for medication storage, as well as spray bottles, storage containers, and more. Packaging companies can utilize dome blow moldings to create caps for various containers used in a variety of industries.
A variety of materials can be used to create a domed shape. Materials that are suitable for dome blowing include; Acrylic, Polycarbonate, Glass, PVC, ABS, and High Impact Polystyrene. Acrylic and polycarbonate are often considered two of the best materials used for dome blowing due to their durability and strength.
When it comes to dome blowing, there are a number of benefits. Some of the advantages of dome blowing are:
- It’s a relatively low-cost option
- A variety of products can be made through dome blowing.
- Products are immediately ready to be used or packed and shipped. No extra assembly required.
There are, of course, some disadvantages to using dome blowing as a manufacturing technique.
- It contributes to the creation of plastic production, which is harmful to the environment if not disposed of correctly.
- There are limitations to the usage of dome blowing.
- Highly dependent on petroleum which is used to create many plastic materials.
As acrylic is considered one of the best materials used for dome blowing, what makes it so special? Acrylic is considered to be highly durable and resistant to damage even with the use of excessive force. This material also gives businesses the opportunity to choose from a wide range of colours. Acrylic domes are also highly versatile, being used for a wide range of applications. However, it can also be used for a variety of large-scale projects that include surveillance, and outdoor locations like playgrounds.
DRAPE FORMING
Drape Forming is a type of thermoforming process which utilises the heating of thermoplastics until they soften and then draping them over a mold to shape it. The thermoplastic will then cool whilst draped over the curved female or male mold, hardening as it cools and setting in shape. Drape forming is typically used for large, plastic components, with acrylic being one of the most commonly used materials for this process.
Acrylic drape forming generally makes curved shapes, applicable in several industries. This technique can be used for the production of signage and retail displays, windshields and other components for the automotive, aerospace and marine sectors, medical devices, and consumer goods, amongst other products.
Perspex is a type of acrylic sheet that can be shaped once heated evenly. As a thermoplastic, acrylic softens when heated and hardens when it cools, and so to shape Perspex sheets methods such as drape forming can be used. Other methods such as vacuum forming and pressure forming can also be used to shape Perspex sheets, utilising the same concept of heating the plastic before shaping it with a mold.
The correct polycarbonate drape forming temperature is between 145-155°C; the oven must be heated to a temperature within this range if drape forming with polycarbonate to soften the plastic enough to shape it, without affecting the integrity of the sheet.
When drape forming Plexiglas, the acrylic sheet must firstly be heated to the correct temperature so that it softens. Once softened, the sheet will be malleable, so it can be removed from the oven and carefully placed over a mold. Some processes may combine these two steps – heating the plastic over a mold so it softens around the shape of it. During the cooling process, the edges of the sheet may begin to curl, so should be clamped, held, or weighted down. A blanket may also be used to slow the cooling process.
Advantages include:
- During the process, the plastic is not stretched, unlike some other thermoforming methods. This means the plastic preserves its thickness and does not incur any weaknesses.
- Thick section materials can also be formed using drape forming.
- The tooling required for drape forming is not complex, which can lower costs, and plastic which is clear or textured will maintain its features after processing.
Some drape forming disadvantages include:
- Depending on the thickness of the plastic, the cooling time can slow down the production of drape formed goods.
- A unique mould will be required to create new shapes, and scrap may be increased due to factoring in clamp and trim areas.
LASER CUTTING & PROFILING
Laser cutting is a process that uses a laser beam to accurately cut materials. The beam is focused on the material, which causes it to vaporize. This vaporization creates a high-pressure gas jet that cuts through the material. Laser cutting is used to cut a wide variety of materials, including metals, plastics, and composites.
Laser cutting can be used to cut a wide variety of materials, including metals, plastics, and composites. Some common examples of materials that can be laser cut include stainless steel, aluminium, brass, copper, titanium, and various types of plastic.
Laser cutting equipment is extremely accurate. In fact, laser cutting is often used for applications where tight tolerances are required.
Laser cutting acrylic is a process that uses a laser beam to cut the material. The laser beam is focused on the material, which causes it to vaporize. This vaporization creates a high-pressure gas jet that cuts through the material. Laser cutting plastic this way is extremely accurate and efficient.
Yes, Perspex can be laser cut. As acrylic it is the type of plastic that can be cut this way. There are a variety of things that can be made by using laser-cut Perspex. Some examples include signs, displays, and packaging.
Laser cutting has a number of advantages over other methods of cutting. These advantages include:
- Laser cutting is extremely accurate. In fact, laser cutting is often used for applications where tight tolerances are required.
- Laser cutting can be used to cut a wide range of materials, including plastics, metals, and composites.
- Laser cutting equipment is delicate and must be handled with care.
- Laser cutting produces harmful fumes and smoke. This smoke can be dangerous to your health if you are not using proper ventilation.
Laser cutting has a number of applications. Some common examples include:
- Cutting metal sheets for use in auto manufacturing
- Cutting plastics for use in signage and displays
- Cutting composite materials for use in aircraft and spacecraft components
- Cutting titanium for use in medical implants
LINE BENDING
Line Bending is a manufacturing process used to create bends within a sheet of plastic. Line bending requires localised heating of the material so that the plastic can be bent at an angle along a heated strip, sometimes referred to as a hot hinge. A former or jig is used to bend the plastic. It is then cooled and retains the shape created. Line bending creates a seamless angle without the need for additional operations such as joining or glueing.
Line bending can be used for a multitude of products. These include display stands, plastic boxes, leaflet dispensers, or furniture such as outdoor furniture or acrylic tables. Line bending creates simple shapes, where the clean look of the product is a primary focus. Whilst line bending is limited to the production of plastic products, a wide range of plastics can be used such as acrylic, Perspex and PET-G.
Advantages of line bending include:
- Line bending does not require additional tooling to create the product as a seamless bend can be created, offering a flawless product.
- Straight bends with small radiuses can be created.
- It is a relatively simple process to undertake, and the plastic can be reheated and reformed if the process is miscalculated, reducing scrap and manufacturing costs.
Disadvantages of line bending include:
- Only simple shapes can be created due to the nature of the method; a line bending machine and former or jig is required to heat and shape the plastic.
- Restriction to the numbers of bends in a single sheet.
- Stress bends can occur which can deform the plastic.
- Additional processes such as cutting may be required.
The process begins with heating the strip heater or line bending machine to the correct temperature for the plastic it will be working with. The area on the plastic sheet to be bent is marked up so it can be aligned correctly with the heating element. The sheet is then laid on the heating element until it has softened; at this point the plastic sheet will be removed and placed on the former or jig where it is bent. The plastic is left in this position until it has cooled and hardened in the desired shape.
Line bending has to be done with a thermoplastic, since this type of plastic can be reheated and reformed numerous times without affecting the integrity of the material. There is a variety of thermoplastics that can be used including:
- polycarbonate (PC)
- foam polyvinyl chloride (foam PVC)
- acrylonitrile butadiene styrene (ABS)
- polypropylene (PP).
- Acrylic sheets such as Perspex and Plexiglass can also be formed by line bending.
A line bending machine provides the heating element, as well as structures to measure and align the plastic being bent to the heating strip. The machines are available in a variety of styles and forms, for simple line bending used within schools to machines for complex, industrial, mass production; it may feature one heating element (typically a resistance wire) or several, depending on the application and requirement.
CNC MACHINING
There are five different types of CNC machines. CNC Lathe Machine, Router machine, Milling Machine, Laser Cutting Machine and Plasma Cutting Machine. Here at ASH Plastics Ltd, we use routing, milling and laser cutting.
Many kinds of materials are used in CNC machines. We, as our name suggests, use mostly plastic materials in our production line. But we do sometimes use alternative materials too. Various metals can be used in a CNC as well as wood, foam and fibreglass.
CNC’s are very efficient in the production process. The computer uses a drawing programme to make sure that the exact same item is produced over and over again, eliminating human error and maintaining accuracy every single time. It also can be set to a certain speed and quality so you can be sure how long a job is going to take and what finish you are going to see.
VACUUM FORMING
Vacuum Forming is a relatively simple thermoforming manufacturing process. A sheet of plastic is heated to become pliable before a vacuum is used to suck the heated material onto a mold. The plastic is then left to cool and harden, maintaining the shape of the mold in the now cooled plastic sheet.
Various types of components can be made this way. Parts for industry, trays such as nut and bolt holders can be formed to a specific size and shape. Automotive components for interior design of vehicles can also be made like this, light covers, seed trays for gardening and growing and so on. We can of course manufacture various types of retail displays and point of sale materials using the vacuum forming method too. You are essentially only limited by your imagination; and anything that can be made into a mold can be produced in this way.
Typically, our molds are made from wood, but they can be manufactured from various types of metal too. Usually something as simple as medium density fibreboard (MDF) can be used as an affordable material during prototyping, this helps keep costs lower.
Vacuum forming can be used with: ABS, HIPS, PET-G, Acrylic, HDPE, polypropylene and polycarbonate.
ACRYLIC MACHINING
Acrylic can get scratched but not very easily. If you need to use acrylic in a harsh environment such as a factory you must accept that over time it is likely to start to show scratches and scuffs. But in most normal environments it should be ok and will take a few knocks and scrapes without showing any significant markings or wear and tear.
We use acrylic for the manufacture of bespoke point of sale units and retail displays. But it can also be used for many things such as boat or shed windows, facias, barriers and enclosures, medical devices, lenses and splashbacks. But the application for acrylic seems almost endless.
Yes, you can. In fact, clear Acrylic can be buffed to a clear finish that is more transparent than glass!
Yes, you can. Acrylic is perfectly safe to be drilled should that be a requirement.
Yes, we use line bending equipment to make sure that we get an even temperature across the area of the acrylic that requires bending. We also make sure that after the material is bent it is held into place in a mold so that it sets at the right angle. It is advised that you get your acrylic bent professionally for the best outcome.
Yes, it is waterproof and can be used in both indoor and outdoor applications.
BONDING: UV GLUING & PLASTIC WELDING
UV light is passed over the bonded materials and this triggers a photochemical reaction that hardens the polymer almost instantly.
There are several advantages to using UV adhesives. These include:
- Reduced energy consumption
- Faster assembly times
- Low levels of volatile organic compounds (VOCs)
- Flexible, stress-absorbing bonds
A high viscosity adhesive is better for gap filling or vertical positions, and UV curing adhesives are better for applications that need a moderate bond line thickness.
PRINTING: UV PRINTING
There is a wide variety of materials that can be printed onto including of course plastic, as well as glass, wood, metal, cardboard and paper. Our primary material to use is acrylic but we can apply digital prints to various substrates, including vinyl.
UV ink is very durable. Its application does affect how long it will last before fading. If used in an outdoor setting, it can last up to 5 years without fading. If the product is laminated or used indoors it can easily last up to 10 years without fading.
UV Printers are the most advanced type of printing for industrial and commercial printers currently. They achieve high quality printing in a minimal time. The UV light ensures that all curing ink is dried immediately meaning no streaks and once dry the print does not crack or flake.
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We work with some of the biggest retail brands in the UK and many smaller independent retailers and businesses and we are ready to take on the next big industry challenge, that might just be your challenge too! Why not get in touch with us today.
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