ITW Trans Tech: PADPRINT: Tooling 101-- A Typical Customer Scenario


	PADPRINT NOTEBOOK Useful Tips & Information © ITW Trans Tech An Illinois Tool Works Company


	CUSTOM TOOLING: Fixture Form Follows Function *Manual-load, cap-cover fixture made of raw aluminum* *Poured urethane insert fixture with vacuum assist* *Control button fixture after hardcoating* • Why Not "Do-It-Yourself" Tooling? • Frequently Asked Questions (FAQs) About Fixtures • More Fixture FAQs • Case Study: Shuttle & Special Fixture (Four-Color Application) Time To Re-Tool? Ask Our Experts! For Tooling, Re-Tooling or Fixture information: Retooling Supervisor: Owen Ault ... 630.909.5777

Tooling 101:
A Typical Customer Scenario

IN THIS competitive decorating industry, our customers are demanding more expertise in providing critical pad printing accessories–– specifically, custom tooling and part-holding fixtures. This requires ITW Trans Tech to be focused on solving customer applications by offering experienced know-how. To illustrate how this process works, here is a typical project scenario:
Handtool housing fixture, empty

Handtool housing fixture made of raw aluminum shown empty and with loaded part.

An order may start with a customer request via phone, fax, e-mail or website contact. We may also receive a sample part to show the application concept for evaluation with the attached question:

"I need a fixture for this part. How much will it cost me and when can I get it?”

Our Tooling Supervisor, Owen Ault is the key contact for generating quotes and orders for all custom tooling and fixtures for existing customers’ machines. With a typical project he begins the preliminary information gathering with a call to the customer: “First, let’s talk about your application. Now, don’t worry if some of these questions are a bit technical. That’s why I’m here to walk you through the process.”

“Sorry," the customer says, "I don’t really know exactly what I need. But since you guys are the experts–– you tell me what will work best.”

Machinist Mike Pidgeon and Supervisor Owen Ault test the fit of part, pad assembly and holding fixture.

Rule Number One: More Information Is Better Than Less.
“Well, let’s see… For starters, our rule of thumb is: ‘More information is better than less.’ So we’ll have to first spell out as many relevant details about the operation as possible. At this early stage of the process, every detail is valuable. These pieces of the puzzle begin to give us a better picture of your application and how to design the best solution. In general, the more complete the information, the faster the project will be finished."

“OK, let’s get some basic facts to determine the application specs: First, will it be a single or multicolor application? And if multi-color, how many colors will be printed and in what sequence?

Second, will a part indexer be used to move the fixture? If so, what type? This will help us to determine if your existing machine can handle printing your sample part."

Master Machinist, Mike Pidgeon

Master Machinist Mike Pidgeon adjusts his precision cutting mill during a tooling project.

Spell Out Specifications
“How about loading: where is the operator going to stand in relation to the machine, and how will the part be loaded into the fixture? Will the part load be manual or automatic?"

“Now we need to analyze your operation and production goals to determine if your fixture should be one-up or two-up. If there are multiple, fixtured parts to be printed, the pitch or distance between the part centers is important to fall within the parameters of a specific standard machine."

“What about the fixture finish: What material is best suited to hold your part? Raw aluminum? Hardcoated? Anodized? Sandblasted? Will it need a plastic insert? How about a UHMW polyethylene or poured urethane? Is the part from a single or multiple cavity mold? All these details will make a big difference in how we design the tooling."

The Science of Artwork
“Now let’s talk about artwork. Will we need to use the artwork for reference in building the fixture or use the fixture for reference in creating the artwork? This may seem like a chicken-or-egg question, but it does make a difference where we begin."

"Do you have an artwork ready or will you need the services of our art and cliché production staff to generate it? Will the art need to be distorted to appear properly once transferred to the part? This is a rather tricky task but our computer artists are skilled at doing it. If so, we will we need to test print the artwork on your sample parts."

“Also, you may or may not need a pad bar assembly–– for multi-part images. If you do, we may be able to use a standard assembly instead of a custom one. Tell me, is this design entirely new or a duplicate of a previous project? If your new tooling has to match up identically with an existing fixture, you may need to send us the original piece."

Retooling Supervisor, Owen Ault

Retooling Supervisor Owen Ault updates the schedule as a recently completed holding fixture is ready to ship.

You Can Quote Me
“That should just about cover it. We’ll fax you the quote for your approval.”

With all this specific information, we can now submit a quote request to our fixture tooling specialist. He will estimate how much time and materials will be required to complete the project. He then returns the part with a quote, the coordinator adds the necessary accessories and the customer is notified.

Once the customer approves the quote and sends us a purchase order, we will give the project the green light and enter the order into our production system.

There are two other necessary customer steps to start the process:
• Send artwork file to our Plate Services department (call us or see the article "Just What Do We Mean By ART?" for preferred electronic formats).
• Send 20 to 25 final production parts for testing. Please avoid sending prototypes due to their inconsistent quality. Our experience has shown that prototypes lack the close tolerances that most applications require.

Once received, the artwork file goes to the Art department where a separate order is created with technical details such as: artwork format, orientation on cliché plate, pitch, layout of operation showing loading position and so on.

Print Lab Tests
Next, a new category of questions must be answered: What plate, what ink, what pad, and so on? If these are unknown at this point, our print lab technician will test several and make a recommendation. Test printing continues with a temporary pad assembly (if necessary) and a temporary polymer plate, etched using the newly created artwork film. Also the sample part substrate is tested for compatibility with recommended inks, usually in black or white.

The production fixture is also used in the specific machine model to test the artwork for any distortion. If necessary, the artwork is then modified and a new film and plate are made to compensate for it.

First Approval, Then Hardcoat
Once the customer’s parts have been correctly printed, the parts are returned to them for approval. At this point, customer input or changes may be necessary. If modifications are requested, the process continues as before, focused on their specific concerns. Once final approval is received, the fixture is given its hardcoat finish and the final steel cliché plates are made. All completed items are then shipped to the customer.

The entire process from quote to delivery usually takes from three to four weeks, based on our receipt of your purchase order, production parts and art file. This timeline can be shortened if all the specifications are ready at the outset, if the artwork is already finished or if the job is relatively simple. The critical factor is the key person asking the right questions and getting as complete information as possible. That is where experience makes the difference, avoids guesswork, and adds value to the product, in this case, your finished fixture.

For more details on our custom tooling and part-holding fixtures, feel free to contact Owen Ault at: www.itwtranstech.com

For Tooling, Re-Tooling or Fixture information:

Retooling Supervisor:
Owen Ault ... 630.909.5777

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