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The torch for The 2017 Ashgabat Asian Indoor and Martial Arts Games

Client: Design Brains Pty Ltd

Services:  CNC Machining, die casting, Injection tooling service, sheet metal, lathe, laser etch, surface finish(polishing, plating, baking paint, gold blocking), assemble, packaging and delivery

Material:  ADC 12, ABS+PC, Flame retarding PA6630%GF, AL 6061, AL 5052

Quantity:  450 sets

Lead Time:  2 weeks for prototype, 30 working days to tooling, 7 working days for parts manufacture, 10 days for surface finish, 5 days for assemble & package.


> Step 1: Two sets of prototypes

Clients want to make two sets of prototypes to check and test at first. This is a torch and must work with every different climate such as wind or rain. So the well fit of each part is quite important.We did some modifications before the production and discussed it with our client to make sure all parts assembled well and function well.

The CNC AL parts with gold plating, CNC ABS+PC parts with paint (two different green colors), the badge also require the gold blocking and the sheet metal part with paint.Then we need to glue these parts together to make sure the parts are strong and no part can fall off.

     

> Step 2:Mass production, assemble, packing and delivery

Manufacture Process: Tool making, die casting, sheet metal,lathe

The top, bottom and foot part in ADC 12 made by die casting process, then polishing and plating the parts in shinny golden.The body and badge in plastic material made by tooling and injection, the top badge part need to be flame retarding.The top badge require gold blocking on the letters.The sheet parts produced by bending and laser cut. The small gas knob machined by lathe with green baking, then laser etch the surface.

Assemble: Assemble the foot with bottom golden by screws and glue,Firstly, gluing the lattice part with the green plastic body part together.Secondly, using the screw to assemble the top badge with the gold top part, then glue the top and bottom part together. Finally glue the small vee part to the torch body.


> Package

Packaging the parts by the non-woven bag firstly to protect the surface, then using the bubble bag to protect, and put them in the box, the box filled with special buckle to hold the parts in position and no spare space in package, so that the parts will not move during the transportation.


Tool making

Die casting process




Die casting parts without remove gates

Die casting parts without gates

Sheet Metal-Laser cut




Sheet metal parts after bent
Injection process






> Surface finish



Polishing  AL parts

Polished  AL parts
Checking the polished parts before plating

Plating

Baking




Baking parts







We will check the part quality before doing the next step, like checking the dimension assemble before doing the surface finish, and checking surface finish before the assembling.


Gold blocking on the letters
Laser etch after baking
CNC lathe AL parts with baking & laser etch




 > Assemble

We used high-temperature resistant adhesives and screws to bond several parts together, we have tested the glues and run test with different temperatures to make sure the parts are well glued and strong.







Final check before package





 > Package

We designed Non-woven bag, Bubble bag and boxes to package the parts and made sure all the parts are well packaged and keep safety during the shipment.

    

5th Asian Indoor & Martial Arts Games Ashgabat 2017,Openning Ceremony
    



Client: Design Brains Pty Ltd

Services:  CNC Machining, die casting, Injection tooling service, sheet metal, lathe, laser etch, surface finish(polishing, plating, baking paint, gold blocking), assemble, packaging and delivery

Material:  ADC 12, ABS+PC, Flame retarding PA6630%GF, AL 6061, AL 5052

Quantity: 450 sets

Lead Time: 2 weeks for prototype, 30 working days to tooling, 7 working days for parts manufacture, 10 days for surface finish, 5 days for assemble & package.


> Step 1: Two sets of prototypes

Clients want to make two sets of prototypes to check and test at first. This is a torch and must work with every different climate such as wind or rain. So the well fit of each part is quite important.We did some modifications before the production and discussed it with our client to make sure all parts assembled well and function well.

The CNC AL parts with gold plating, CNC ABS+PC parts with paint (two different green colors), the badge also require the gold blocking and the sheet metal part with paint.Then we need to glue these parts together to make sure the parts are strong and no part can fall off.


> Step 2:Mass production, assemble, packing and delivery

Manufacture Process: Tool making, die casting, sheet metal,lathe

The top, bottom and foot part in ADC 12 made by die casting process, then polishing and plating the parts in shinny golden.The body and badge in plastic material made by tooling and injection, the top badge part need to be flame retarding.The top badge require gold blocking on the letters.The sheet parts produced by bending and laser cut. The small gas knob machined by lathe with green baking, then laser etch the surface.

Assemble: Assemble the foot with bottom golden by screws and glue,Firstly, gluing the lattice part with the green plastic body part together.Secondly, using the screw to assemble the top badge with the gold top part, then glue the top and bottom part together. Finally glue the small vee part to the torch body.


> Package

Packaging the parts by the non-woven bag firstly to protect the surface, then using the bubble bag to protect, and put them in the box, the box filled with special buckle to hold the parts in position and no spare space in package, so that the parts will not move during the transportation.


Tool making




Die casting process


Die casting parts without remove gates


Die casting parts without gates


Sheet Metal-Laser cut


Sheet metal parts after bent


Injection process


> Surface finish

Polishing  AL parts

Polished  AL parts

Checking the polished parts before plating

Plating

Baking

Baking parts


We will check the part quality before doing the next step, like checking the dimension assemble before doing the surface finish, and checking surface finish before the assembling.

Gold blocking on the letters

Laser etch after baking

CNC lathe AL parts with baking & laser etch


> Assemble

We used high-temperature resistant adhesives and screws to bond several parts together, we have tested the glues and run test with different temperatures to make sure the parts are well glued and strong.

Final check before package


 > Package

We designed Non-woven bag, Bubble bag and boxes to package the parts and made sure all the parts are well packaged and keep safety during the shipment.


5th Asian Indoor & Martial Arts Games Ashgabat 2017,Openning Ceremony