These films are made by patterned master rolls. Master rolls are pressed on films and uniques patterns are made on film surface.
Paterns on master rolls are made mechanichally. They are so fine that this processing is quite expensive.
When this roll is used in mass production, abrasion is found on the master roll surface due to repeated use. Then the master roll has to be made again. It leads to the soaring roll cost.
For this reason, there is for Film Transferin the film market on the cost effective master proessing.
▲Fine seamless pattern belt
We, Dymco, found out this cost-effective manufacturing process.
The outline of the process is like this:
１. The Master Roll
The pattern of the master roll is confidential matter for almost all users and quite expensive, in most cases the original master roll is supplied to Dymco from customers. However, if we are asked, we can make patterns, too.
2. The Mother Sleeve
Nickel plating (electroforming) is performed on the surface of the master roll. This outer plated area is 'mother sleeve'. Thickness of this mother sleeve is 0.1 to 0.3mm.
3. Separation of the 'Mother Sleeve' from the Master Roll
The electroformed mother sleeve fits perfectly the master roll and those two are completely united. They are separated by Dymco' original separator unit.
4. The Master Roll
The master roll remains. It is stored with care until we make mother sleeve again.
5. Creation of Replica Sleeve
The separated mother sleeve, its inside is covered patterns made by electroforming.
Then we do electroforming once again in the inner surface with our original unit.
The outer surface is the mother sleeve and its inside is another sleeve, we call 'replica sleeve.'
6. Separation of the Replics Sleeve from the Mother Sleeve
They fit each other. They are separated by our another original separator.
8. A certain number of replica sleeves are produced and stored. One replica sleeve comes to the end of life, this replica is replaced by another replica. This way the master roll is saved from abrasion.
The process to make replica sleeves is quite long and complicated .
We do have lots of discussions with customers.
DYMCO Major Products: Steel Belts Metal Belts Stainless Steel Belts Steel Belt Conveyor
Stainless Steel Belt Conveyor Food Conveyor Metal Sleeve Positioning Conveyor High tensile Stainless Steel Belts
Major Applications: Suction Transport Transport in Clean Rooms Electronic Parts Transport Food Transport Power Transmission