Hard Enamel
Hard Enamel (also known as Cloisonne) originated
thousands of years ago, as was originally used to decorate vases.
Hard Enamel consists of a powder of
glass like mixture. Each colour is hand filled with a tiny spoon onto the copper
recess area stamped by a die. After fusion, it resists scratching by knife or
even heating to 800 degrees. It is renowned for its jewellery like finish, immortality
and limited
natural supply, making it an ideal method in the production of pins, emblems, and
various collectible memorabilia.
For each colour ordered, a pin has to undergo one time
direct heating over 1700F (800°C) before the powder can melt and be
crystallized. For example, if there are 4 colours, the same pin has to undergo
4 baking processes of one colour after the other.
Features:
- preservable for over 100 years with ceramic-likened glaze
- resistant
to scratch, heat, humidity & acidic chemicals (however limited in choice of
colours)
Colour chart is
available on “AOKI” or “FLOWER VASE”.
Matching metal: is copper which capable to endure similar high temperature
but curved a little after baking.
Production Process Steps:
Customer artwork >Develop negative film > Etching metal
plate
> Carving die/mold > Stamping design on metal > Cutting out design > Cleaning by acidic chemical >
Colouring > Baking > Grinding spilled enamel > Soldering attachment > Polishing
> Second cleaning by ultrasonic water > Plating > Packaging
Imitation Enamel
Imitation Enamel is similar in production to traditional cloisonne (Hard
Enamel) except that a special resin is
utilised to provide colours instead of the natural cloisonne colour. Colours can be
matched to Pantone Colours in this type of pin. The design is die stamped out
copper pieces, in a true cloisonne pin.
Imitation Enamel was only invented in 1985 to meet the
overwhelming demand for hard enamel. The synthetic pigments give a gorgeous appearance
which is very close
to Hard enamel, but more shiny. The prime advantage of Imitation Enamel is the
ability to specifically choose colours according to the PMS (Pantone®) colour
chart.
Features:
- 90% correlation and appearance to hard enamel
- non-resistant to scratch nor heat
over 212F(100°C)
- More shiny, colourful and smooth than Hard Enamel
Matching Metal: Copper
Production Process Steps:
Customer artwork > Develop negative film > Etching metal
plate > Carving die/mold
> Stamping design on metal > Cutting out design > Soldering attachment >
Cleaning by acidic chemical > Colouring > Baking > Grinding spilled enamel >
Polishing > Second cleaning by ultrasonic water > Plating > Packaging
Soft Enamel
This represents one of the most popular and cost
effective production processes, especially when finishing on Iron.
The colour is a rich PMS base, which delivers a brilliant
shine on copper, iron & aluminium - through a process of stamping or photo etching.
Soft Enamel Stamped Copper / Brass
Soft Enamel Copper uses paint pigments similar to those applied on
a car, representing a more cost effective option than hard or imitation enamel.
This process only requires 100°C degree
to dry the paints during a 4 - 5 minute oven heat. The unique raised rims
render a refreshing metallic experience, giving years of treasured ownership to
the customer.
Designs that need a thin
border or outline are perfect to apply soft enamel to.
Similar to Imitation Enamel, however:
- Plating takes place before colouring to speed up
the process
- A fabric wheel is used in polishing
- Epoxy may be added, depending on order requirement
Features:
- Shiny and smooth in surface, but vulnerable to scratch and high
temperatures
- Epoxy (a doom of transparent plastic) is often applied to protect
the pins from scratching. The paint is thinner than Hard/Imitation Enamel and
lower than the raised metal rim. Colour choices are available according to the Pantone number
(PMS).
Matching Metal: Copper (1.2mm+), Brass(0.8mm+), Iron(0.8mm+),
Aluminum(0.8mm+), Stainless Steel,
Production Process Steps:
Customer artwork > Develop negative film > Etching metal Plate > Carving die/mold
> Stamping design on metal > Cutting out design > Soldering attachment >
Cleaning > Polishing > Plating > Colouring > Baking > Filling epoxy (optional) >
Packaging
Stamped Iron Soft Enamel
With Soft Enamel Stamped Iron, these pins are very similar in production to the soft enamel, except
that the material used is iron instead of copper. Pantone colours are used and
can be chosen for these types of pins. These forms one of the lowest cost
processing options of all the different types of
pins available today. The surface of an iron pin may be covered with epoxy to
protect the colours.
Photo Etched Soft Enamel
Soft Enamel Photo Etched uses photographic negative techniques to produce
these type of pins. The negatives are made to the exact size of the design and
laid out across the surface of the copper metal, which is then dipped into a
chemical solution to etch the image into the metal - at which stage colour can be
added. The colours are applied to all etched areas before the metal is placed into the oven. A clear epoxy coating
can be added to protect the soft enamel colours.
Soft Enamel Stamped without Colouring
With these high-polished pins, they do not have their recesses filled with enamel
paints. Instead the recesses of these crafted pins are finished with
sandblasting or a foggy process to achieve a "brushed" effect. Then the raised areas are
highly polished for a very shiny presentation.
Stamping without colour means the colouring is
undertaken by electro-plating instead of enamel or
paint.
Plating Options:
- Gold
- Silver
- Nickel
- Chrome
- Black Nickel
- Copper
- Black Dye in
either shiny
- Antique or 2-tone finishes
- Foggy
- Sandblasted
- Granulation
This design provides a genuine taste of metal by metallic
colour & heavy weight.
This is most commonly applied to coins, medals, pins & badges.
Matching Metal: Copper(1.2mm+)
Production Process Steps:
Similar to Soft Enamel above, however:
- without the Colouring & Baking processes
- Epoxy is seldom applied.
Printed Pins
Silk Screen and Offset printed pins allow for special logos and designs to be
used, without the need for fine gold or silver plating around each colour.
Colours
are silk screened onto a bass material one by one at each time, just like
creating a T-shirt. A final clear epoxy coating should be added to protect the
colours.
With industrial strength capabilities and host of design
options, we look forward to producing your order!
