Custom Machines Case Studies

Custom Machine Design Engineering for Cutting Edge Toy Manufacturer

custom-spraying-deviceA cutting edge toy manufacturer required an automated way to coat plastic toys with custom 3D printed doll faces. They needed to increase production rates and eliminate human error in spraying. EPIC developed a machine design that provided a mechanical means of spraying and curing doll faces at a modest cost. The final solution was fabricated in EPIC’s machine shop and installed at the client’s facility after Factory Acceptance Testing (FAT) testing.

KEY FEATURES: Two multi axis spray platforms, UV light curing system, forty two custom mounting fixtures, guided conveying system, custom gearbox and cam assembly

Client: Possibility Place

Industry: Toy Manufacturing

Key Engineering Features

  • A three step industrial spray coating system does the following:
    • First coat of matte finish is applied to doll faces passing on a conveyer
    • Doll faces pass under a UV light station to cure the matte coat
    • A recirculating system applies hardening clear-coat to the doll faces in the third step. The system recirculates to prevent fouling in the inner components of the machine
    • In the final step, dolls again pass under the UV light curing system to harden doll faces for final installation
  • Custom mounting fixtures allow 30 degrees of tilt on the x and y axis to achieve an even coating
    • Gearbox and Cam assembly are responsible for manipulating the custom mounting fixtures
  • PLC

custom-machines-spraying-deviceCore Challenges:

  • Providing the simplest solution to replicate the action of a human spraying a spherical surface
  • Demand was increasing every day, so the project had to be completed on a very short timeline so that store shelves did not run out of toys.
  • Keeping the cost of the custom solution modest for the customer

EPIC’s Proven Solution:

In danger of running out of their doll stock, Possibility Place contacted EPIC with the need for a cost effective but fast solution. EPIC quickly completed machine design for a solution to coat custom 3D doll faces that would increase throughput, preventing shipping shortages.

Replicating the motion of a human spraying on a doll face was the main challenge for EPIC. While a robotic solution might seem logical, the cost was prohibitive for the client. Instead, EPIC designed the system to use simple mechanical means to replicate the human motion of spraying the surface of the doll face. The solution delivered by EPIC uses a custom cam assembly to allow the doll head fixtures to rotate 30 degrees along the x and y axis.

After the first coat is applied to the doll face, they pass under an ultra violet curing station. After the first coat is cured, the doll face receives a second coat and is cured a second time. The custom machine increased manufacturing speed, allowing a higher daily output that could keep up with growing toy demand. An added benefit of the mechanical application was improved product consistency, achieved because of the uniform motion of the custom cam assembly that manipulated the doll fixtures.

Why EPIC Custom Machines

A custom machine design firm helps you design, fabricate and integrate an appropriate custom solution that meets your unique need. EPIC believes we can help you “Make it Happen” by:

  • Utilizing Front-End Engineering to ensure that the proper steps are taken during project scope development
  • Appointing a single point of direct contact during the entirety of the project
  • Maintaining an open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
  • Imparting a transfer of knowledge (not just a basic training) for the machines and equipment we provide

Find a better solution. Contact EPIC or learn about custom machine design

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