Technologies

Get an overview of what technologies Mekoprint possesses, and learn about the values we work with. We meet our customers' challenges and we are known for our willingness to expand our technology inventory. Therefore, contact us even if we do not immediately appear to meet your production technology requirements at the moment.

Anodisation

ANODISERING:

The anodising of aluminium is an electrochemical process in which the surface is transformed into a hard, decorative protective aluminium oxide layer. A non-electrically conductive surface with increased corrosion resistance is achieved. Mekoprint conduct anodisation in the natural and black colours (and other colours are also possible when the number of units ordered is large). 

The anodisation layer thickness is 12-30mm, depending on colour and material.

 

FORMATS:

The parts may not exceed 2300mm x 700mm.

MATERIALS:

All aluminium alloys can be anodised. However, not all alloys are equally cosmetically suitable for anodisation.

Automatic clip, strip, crimp and labeling

SHORTENING, STRIP, CRIMP AND LABELING

Shortening, strip, crimp and labelling is done during the same procedure and is an extremely cost-effective production process. 

Wiring overviews from our customers are used directly from the start of production and are loaded into the machines as a cut order. 

This contributes to keep administrative processing at a minimum. 

 

THRESHOLDS

With electronics solutions, we can shorten and crimp single wires that measure 0.08mm2 -2.50mm2. 

In industrial solutions, we can shorten, crimp and label that measure 0.5mm2 -6.0mm2. 

The labelling can be in black or white text using an inkjet. The ink that is used is tested and approved in accordance with SAE J2202. 
 
MATERIALS
All kinds of single wiring

 

Bending

BENDING

Edge and panel bending are flexible and accurate methods of bending sheet metal. Mekoprint has several edge bending machines as well as a fully automated panel bending machine.

FORMATS:

A maximum bending length of 3000mm.

Materials:

All materials

Casting

Casting

Low pressure casting is a fast, gentle and environmentally-friendly method for protecting electronics from mechanical stresses. The material is also electrically insulating and chemically neutral. 

The tools that are used are aluminium tools, and have an interesting price compared to traditional injecting moulding tools. 

The method is also used for the coating of plugs to achieve IP tightness or lightening, for coating junctions or for unloaders at panel passages or the like.

 

Chemical etching

Chemical etching is a process flow consisting of several processing steps. It can be utilised with a number of different materials.

Typically, this process uses nickel silver, stainless steel, beryllium copper, tin bronze or brass.

The materials are typically on 500mm x 610mm sheets or on rolls when there is a high volume.

 

Read more


 

The etching process is particularly suitable for producing parts that are 0.05-1.0mm thick, and makes it possible for making complex products which can not be produced with traditional plate processing.

The production of tools is not required. Therefore, the prototype delivery time is very short–usually not more than 2-3 days.

Moreover, the products are entirely burr and tension free, and can be delivered in strips or in sheets ready for subsequent automatic installation.

 

 

Clips and clamps

Clips and Clamps

Clipping and clamping single wires and multicore wires in the same procedure.

Clipping and stripping coax cables in several steps so that they are ready for the installation of matching plugs.

 

Formats

Single wires 35.0 mm2
Multi wires up to Ø 12 mm. 
RG316 coax cables to, e.g., RG6 Quad shield.

 

Coating

Coating occurs on flexible substrates in an in-line process and roll-to-roll in a controlled environment in which the process is optimised for a high consistent level of quality.
The coating can be done on various substrates using solvent-based materials. The substrates can be coated at full width in patterned stripes along the direction of the lane.

The production facility is equipped with contacts and convection ovens for hardening the applied material.
Prior to coating, the roll can be pre-treated with, e.g. contact cleaning and/or corona treatment, including on the conductive materials.

 

Read more about our production options, materials and technologies


Materials

•    Polyester (PET)
•    Polycarbonate (PC)
•    Polyethylene Naphthalate (PEN)
•    PET coated paper


Technologies

•    Automated screen printing (roll-to-roll)
•    1, 2 and 3 sections of coating, slot die coating, rotations flexo print and rotations engraving print
•    One and double-sided coating
•    UV, IR and convection ovens


Printing pastes and ink

•    Conductive silver
•    Conductive graphite
•    Etch resistance
•    Solder mask
•    Dielectric ink
•    Graphic ink
•    Transparent conductive materials
•    Semi-solid electrolytes
•    Semi-conductive polymers
•    Lacquer
•    Printable adhesives and spacers

 


Formats

•    Material thickness: 50-500µm
•    Layer thickness: 1-200µm
•    Roll width: Up to 750mm
•    Line width and distance: down to 1mm
•    Line width and distance: down to 200 µm


Finishing

•    Screen printing
•    Lamination
•    Slitting
•    Punching
•    Embossing
•    Laser cutting

Coil punching

  • COIL PUNCHING
  • THICKNESS AND FORMATS
  • MATERIALS

Coil punching is used with large quantities. Depending on the part, it would be worthwhile price wise to make coil tools when approximately 20,000 parts are ordered per year.

It is possible to punch, hole, emboss, bend, deep draw and make M2 to M12.

 

Material thickness.
Stainless steel, 0.5-3mm.
Iron, 0.5-5mm.
Aluminium, 0.5-6mm.

 

Read more


 

Stroke length 20-160mm

Punching capacity: 20-240 strokes/min.

Maximum coil width: 800mm

Press level: 1300x1600mm.

Minimum part width: 20-30mm in 1-2mm thickness.

Maximum part width: 800mm.

Minimum part length: 10mm.

Maximum part length: 1500mm, depending on the shape of the part. 

 

Aluminium
Steel
Stainless steel 

 

 

 

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Cutting of foils and films-sheet

 

When cutting large amounts of self-adhesive foils and films in sheets, Mekoprint utilizes a fully automatic die-cutter. When amounts are smaller, other semi-automatic cutters can be used in order to keep start-up costs low.

Self-adhesive foils and films in sheets can be cut wholly or partly with a standard tolerance of +/- 0,3mm or less – depending on the customer’s demands for precision.

Die-cutting (wholly cut) is used when outlining a label or when cutting displays, holes or buttons in an overlay.

Read more about materials and processes


Kiss-cutting (partly cut) can be done from the backside or from the frontside. If kiss-cutting is done from the backside, it is typically done to ease the dismounting of the film that protects the adhesive when the printed part is to be adhered. If kiss-cutting is done from the frontside, it may be to ease identification of the printed part by printing a bar and QR code on the frontside which can be then removed when the part is being mounted.

When cutting large quantities, die- and kiss-cutting is a cost-effective technology as it requires a unique cutting tool which can then be used many times to lower the unit cost. When cutting smaller quantities, laser cutting may be a less costly technology as it does not require a cutting tool, but only digital artwork of the part to be cut.

Materials

  • Polyester (PET)
  • Polycarbonat (PC)
  • Polyvinylklorid (PVC)


MACHINE PROCESSES

  • Automated sheet feeder
  • Die- and kiss-cutting
  • Laser-controlled, automated sheet positioning
  • Automated unmounting and removal of parts
  • Consistent and uniform reproduction of parts to be printed again and again
  • High precision – tolerances of  +/- 0.1 mm


Part sizes

  • Minimum 150 x 300 mm
  • Maximum 700 x 1000 mm

Digital Screen making

Digital screen making is an automated, fully digitalized process which substitutes the conventional manufacture of screens for silk screen printing.

The process is digitalized from the upload of the artwork to the pc to the making of the finished screen – all in one process in much fewer steps than by conventional screen making.

TEcHNOLOGIES

Digital screen making is made up of the following automated steps:

  • Ripping
  • Computer-to-screen imaging
    • In-line developing directly onto the screen in a resolution of 1270 dpi

FORMATs

Maximum screen format                           1400 x 1200 mm
Maximum exposure format                       1000 x 1000 mm

Eccentric punching

  • ECCENTRIC PUNCHING
  • THICKNESS AND FORMATS
  • MATERIALS
  • POLAND

Eccentric punching is used for smaller order quantities in which making coil tools is not worthwhile.
One can punch, hole, emboss, bend, insert rivets and TOX, and make low winding. 
In these processes, only small tolerances will be achievable as there are fixed tools and no manual bending is employed.

 

Material thickness is dependant on the size of the part.
Stainless steel, 0.5-4mm.
Iron, 0.5-10mm.
Aluminium, 0.5-12mm.

 

Read more


 

The minimum and maximum size of each part is dependant on the shape of the part.
Various 8-125 ton eccentric presses.
An 8 ton eccentric press with a press level of 350x250mm and with a stroke length of up to 46mm.
An 125 ton eccentric press with a press level of 840x640m and with a stroke length of up to 112mm.

 

 

Iron
Stainless steel
Aluminium 
Copper
Brass 
Nickel silver 
Tinplate
Punching is also possible with aluminium profiles.

Mekoprint has an 8 ton eccentric press and a 4 ton eccentric press in Poland. An eccentric or hydraulic press can be installed on a robot for a minimum amount of manning is required.
It is also possible to create production cells in which several machine types are connected to a robot. 
With small parts of up to 1mm thickness and 100mm width, it is possible to set up mobile coil feeding on eccentric presses so that punching can be done.

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El-test

The printed part's functionality can be tested in different ways. Testing of the printing can be done at all phases of production. We also offer a final testing of the finished part as well as continuous testing during the production process.

 

TESTING OF PARTS (ROLL-TO-ROLL)

•    Resistance measurements
•    Broken conductive lane measurements
•    Short-circuited conductor lane measurements
•    Component measurements

 
TESTING OF PARTS (SHEET)

•    Resistance measurements
•    Broken conductive lane measurements
•    Short-circuited conductor lane measurements
•    Component measurements
•    Key functionality measurements
•    Diode functionality measurements

Flexprint

In close collaboration with its customers, Mekoprint develops and produces simple one and double-sided high-volume flex print using screen printing and etching technology.
Based on the customer's layout, Mekoprint delivers an optimised, lean and competitive roll-to-roll solution ready for further processing.

 

Read more about our production options, materials and tehcnologies


MATERIALS
•    Copper
•    Aluminium
•    Hybrid metal alloys

TECHNOLOGIES
•    Automated roll-to-roll production
•    One and double-sided
•    Etch resistance
•    Solder mask

FORMATS
•    Roll width: Up to 610 mm
•    Not possible to through plate

Hemming wire harnesses

Hemming wire harnesses

Using pin tables or other fixtures, various single wires and cables are collected for ready plug-and-play solutions. 
They can be collected together with cable ties, wallpaper with fabric tape or collected in flex pipes with fittings at all endings or branchings. 

Wire harnesses are tested for correct placement of connections. This ensures that the customer does not experience malfunctions due to wire harnesses from Mekoprint.

 

Lamination

  • ROLL-TO-ROLL PRODUCTION
  • SHEET PRODUCTION

ROLL-TO-ROLL PRODUCTION

Using camera monitoring, the lamination of foils in our roll-to-roll production is carried out with a high degree of precision.  

WE CAN LAMINATE

- Adhesives
- Spacers
- Fibre optics

Everything in mode of production can be carried out in the same process. For example, spacers can be laminated and stopped at the same time and then the parts can be stripped of backing paper.

SHEET PRODUCTION

Die-cut or whole sheets can be laminated with high precision using CTS machines or traditional laminators.  

WE CAN LAMINATE

- Adhesives
- Spacers
- Fibre optics
- Lines

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Laser cutting metals

  • LASERCUTTING
  • THICKNESS AND FORMATS
  • MATERIALS

A fast and flexible manufacturing method which surpasses CNC punching in terms of the parameters set-up time, material thickness and tool costs.  Fibre laser cutting is an environmentally-friendly production method as it uses a minimal amount of energy and requires no oil lubrication.

Maximum plate format: 1500 x 3000mm
Plate thickness:
Iron        0.5-20mm
Stainless steel        0.5-15mm
Coated iron        0.5-6mm
Aluminium    al99.5    0.5-15mm
Brass (not all types)    0.5-8mm
Copper (not all types)    0.5-8mm

 

Iron
Stainless steel
Coated iron

 

 

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Laser cutting of flexible foils

Fine contours

We can quickly laser cut flexible foils in our roll-to-roll production or using laser tables.

With laser cutting is possible to cut out fine contours, which would be difficult to cut out otherwise, with a high degree of precision. 

 

Laser tables

For smaller tasks, laser cutting has an economic advantage over punching. With smaller series, start-up costs with the use of laser tables are substantially reduced when compared to punching.

At the same time, the laser table makes it possible to carry out rapid prototype processing without developing and producing tools.

When using camera marks, laser cutting can be done with a high degree of precision on a number of different materials and thicknesses.

 

Roll-to-roll 

With high-volume productions, we can, using the same precision, laser cut on our roll-to-roll system.

With this production method, there can be a limitation as to the thickness of the part. If the limitation is exceeded, the laser table is used.

 

Laser welding

LASER WELDING

Laser welding is a very accurate welding method for the welding together of many different types of parts. Mekoprint has great experience in laser welding, mastering both tig welds and traditional full welds. As do spot welds, tig welds join two plates or one plate on a massive part together.

At Mekoprint, laser welding is done without using filler materials, so that the welds are very small, which means that they normally do not need to be ground after welding. Laser welding adds very little heat to the surrounding material and therefore deformations rarely form in the materials and they remain in their original form.

 

THICKNESS AND FORMATS

Plate thickness:

Depends largely on how strong the weld should be and so there is no true maximum thickness. 


Part size:

The turning table direction sets the limitation on the part size to 1640x1000mm.

 

MATERIALS

The vast majority of metals. 
Iron and stainless steel are particularly suitable.

 

Milling

  • MILLING
  • FORMATS
  • MATERIALS

Milling/cutting are first and foremost used for the production of products that are too complex to produce via sheet metal working, or for the preparation of extruded standard or customised profiles. 

Read more


 

 
The processing itself is CNC-controlled and runs on CAD/CAM systems which are directly based on the customer's 3D drawing of the product.

CAD/CAM systems make it possible for us to make complex fixtures, thus ensuring a high degree of fixation for the product being produced, and at the same time to make simulations that can prevent production errors.
Mekoprint utilises the U.S.-made CHICK® tensioning system for making product specific fixtures that can quickly be tensioned in a standard system.

This ensures highly flexible production and at the same time allows for a great amount of repetitive activity, and therefore reduces rejection and start-up costs. It makes it profitable for Mekoprint to produce smaller series sizes. In addition, we ourselves manufacture part part specific tension fixtures–either vacuum fixtures for sheet metal working or specially processed fixtures with quick release for more complex products. The processing itself is done by the tools which based on Mekoprint's experience are the best choice for the task at hand. 

If the series size or production design so requires, Mekoprint will have special tools made specifically for the product. This allows for a great amount of repetitive activity and the opportunity to keep very narrow tolerances.

 

Mekoprint's wide-ranging machine inventory includes many different dimensions and shapes. This versatility enables the production of a multitude of products–from the smallest at a few millimetres in size to products up to 3000mm in size.

 

In the cutting field, there are not so many machines available. This limits what materials can be processed and cutting speed in combination with the right tools. Mekoprint primarily focuses on working with aluminium, iron and stainless steel but our production can be adjusted for other materials.

 

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Passivation with SURTECH 650

PASSIVATION WITH SURTEC 650

SurTec 650 is a trivalent chromium compound for the surface treating of aluminium which is obtained using a dipping process. The treatment is electrically conductive and is an excellent pre-treatment for powder coating. SurTec fulfils the corrosion requirements in MIL-DTL-81706-B and MIL5541-F. The colour is transparent to pale blue/purple.

FORMATS

The parts may not exceed 2300mm x 700mm.

MATERIALS

Various aluminium alloys both from plates and mouldings.

Powder coating

  • POWDER COATING
  • FORMATS
  • MATERIALS

Powder coating is done on a fully automatic powder coating installation.

At Mekoprint we offer powder coating in all RAL colours as well as many different and excellent surface structures such as rough, smooth and metallic finish.  

Read more


 

Pre-treatment:
To achieve a good powder coating, the parts must be clean. Mekoprint phosphates parts directly on the powder coating line before the powder is applied in the paint cabin.

 

We lacquer parts that are up to 1500mm x 1200 mm.

Stainless steel
Aluminium
Galvanised iron
Iron

 

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Pressure details

PRESSURE DETAILS

The insertion of pressure details is done with parts made principally of plates on which are, e.g., threaded or with bushings.

The process is very precise and safe and can be used with most part geometries. 

FORMATS

Plate thickness between 1-5mm.

MATERIALS

Iron
Stainless steel
Aluminium 

Profile saw

PROFILE SAW

Mekoprint has five saw types–Eisel, Panda, Jupiter and an automatic saw. The raw material is automatically fed. 


FORMATS

Mekoprint handles 6m raw profiles both in stock and shortens profiles.
The maximum size of the profiles Mekoprint can shorten depends on the saw type.
At large widths: Maximum 300mm wide x 50mm high.
At large heights: Maximum 150mm wide x 127mm high.


MATERIALS

Aluminium profiles
Steel
Stainless steel
Plastic

Punching

  • PUNCHING
  • FORMATS
  • MATERIALS

CNC punching is used for plate working in which parts are punched out of plates, often before they are bent into their final shape. In addition to punching parts, punching machines are also used for manufacturing winding, cable clamps, gills, countersinks and thread.

Read more


 

The combination SL4 machine is good for parts with many holes and a non-punching-friendly outer contour.
The presses can be CNC punching machines for plate working, in which the parts are punched out of plates, and can in addition perform deep drawing and insert, e.g., rivets, pressure details or TOX.

 

 

Thresholds for CNC punching:

Maximum plate size:
Maximum width of 1500mm and maximum length of 3000mm

Read more


 

Plate thickness:

Aluminium, iron, brass, copper, aluminium zinc: 0.5-5mm.
Stainless steel: 0.5-2.0mm.

 

Thresholds for hydraulic presses:

Maximum plate format of 1000x1000mm
Material thickness. Dependant on the size of the part and the final shape.
Stainless steel, 0.5-4mm.
Iron, 0.5-10mm.
Aluminium, 0.5-12mm.

 

Aluminium 
Stainless steel
Iron (also coated iron)
Brass
Copper

 

 

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Punching of flexible foils

By punching parts on flexible foils, it is possible to fully tailor the production in accordance with the customer's desires and specifications.  Punching can be done all the way through the parts or to a specific depth. We offer punching with tolerances of ± 0.05mm to ± 0.3mm, depending on the customer's desire for precision. 

Mekoprint's roll-to-roll production makes it possible to punch at high-volume directly on the production equipment. The parts are stripped of spills and ready for delivery on rolls that are ready for direct installation in the customer's production. 


Read more about punching types and tolerances


MAGNETIC PRECISION PUNCHING

•    Tolerance: ± 0.05mm
•    Precise punching
•    Inexpensive tools

 

 

PRECO PUNCHING

•    Tolerance: ± 0.1mm
•    High quality
•    High durability

 

Hard Plastic

•    Tolerance: ± 0.1mm
•    Very stable

 

STANDARD WOOD TOOLS

•    Tolerance: ± 0,3 mm

Roll-to-roll production

SCREEN PRINTING AND COATING

Screen printing and coating on flexible foils in high-volume production is one of Mekoprint's core competences. We call it roll-to-roll production. Mekoprint's facility allows for roll-to-roll production and post-processing.

We handle screen printing, coating, etching, laminating, punching, slitting and embossing flexible materials.

The finished product is delivered on rolls for further processing or integration in total solutions at the customer's location.

AUTOMATED AND NON-CONTACT

With a press on our roll-to-roll equipment, camera control can be activated, ensuring a high degree of precision at each printing.

At the same time, it is possible to perform a 100% non-contact test of the printed switch in which any part errors are automatically measured.

 

COST OPTIMISATION WITH HIGH-VOLUME PRODUCTIONS

Roll-to-roll production can be advantageously used with the high-volume production of  homogeneous products.

The process is characterised by a high degree of automation, which is ensured throughout the production chain.

Our customers thereby gain lower costs of each item and a lower total cost of the total production, as with other forms of production.

Screen printing on flexible foils

Screen printing on flexible foils is one of Mekoprint's core competences. We advantageously for the customer optimise the process and offer printing on sheets as well as in automated roll-to-roll production installations.
Irrespective of the production form, Mekoprint's end product is optimised for direct pick-and-place a the customer's location.

Read more about our production options, materials and tehcnologies


 

 

Materials

•    Polyester (PET)
•    Polycarbonate (PC)
•    Polyethylene Naphthalate (PEN)

 

Technologies

•    Automated screen printing (roll-to-roll)
•    1, 2 and 3 section printing
•    One and double-sided prints
•    UV, IR and convection ovens
•    Non-through holes

 

Printing materials

•    Printing colours
•    Conductive silver
•    Conductive graphite
•    Etch resistance
•    Solder mask
•    Dielectric ink
•    Graphic ink
•    Transparent conductive ink
•    Semisolid electrolytes
•    Semi-conductive polymers
•    Lacquer

 

Formats

  • Material thickness: 50-500µm
  • Roll width: Up to 750mm
  • Line width and distance: down to 50 µm

 

Finishing

•    Lamination
•    Laser cutting
•    Punching
•    Slitting
•    Embossing
•    El-test
•    Vision test

Screen printing on metal

Screen printing

Multi-colour printing is possible, possibly through penetrations between colour changes.

Mekoprint can also seal aluminium, which is a very durable printing in the anodised layer.

Read more about formats and materials



 

FORMATS

There are no generally applicable thresholds for screen printing. It always depends on the part geometry and the pressure. Today, Mekoprint conducts semi-automatic screen printing on parts which are a few millimetres to over a meter in size.

 

MATERIALS

Metal

Stainless steel
Raw aluminium, surtec treated, anodised or pressure sealed
Galvanised/chromated iron plate
Lacquered plates

 

 

Plast

Polyester (PET)
Polycarbonat (PC)
Polyethylene Naphthalate (PEN)
Acryl

Semi-automatic strip and crimp

Semi-automatic strip and crimp

Used with multicore cables to strip inner conductors and crimp the terminals in the same process. 

Also used for installing small terminals, as the conductors are fixed and tailored to the terminal during the process.

THRESHOLDS

The process can be used on conductors measuring 0.05 mm2 -4.0 mm2 in size. 

Slitting

In flexible foil slitting, wide rolls are divided in lanes. According to the customer's desires and specifications, the wide roll is divided into smaller rolls that fit directly in the customer's production facilities. 

It is possible to slit the entire foil or only the backing paper to make installation of the parts at the customer's location easy.

Soldering/ Tinning

The soldering of plugs, smaller PCB solutions, tinning of conductors for installation at the customer's location, etc.

Vision testing

Vision testing of finished printed parts on flexible foils can be done for particularly critical parts.

Weld stags

Weld stags

Weld stags and bushings are applied where normally these are to be invisible on the opposite side, often in the front panels or the like.


Read more about formats and materials


 

FORMATS

The maximum part size is 1000 x 750mm (larger parts can be affixed with a handgun). 
The minimum plate thickness is 1.0mm.
The thread size in weld stags or bushings is M2-M8.

 

MATERIALS

Iron
Stainless steel
Aluminium
Other metals are also possible but weld stags or bushings are not possible in all metals.

 

Welding

Welding

Welding is a good bonding method when a junction is to be entirely closed and tight, as with, e.g., electronic cabinets, liquid containers or because of reasons of design.

Mekoprint uses TIG, MIG and MAG welding, with and without added material. When TIG and MIG are used in both non-active protective gasses in the welding, e.g., argon or helium, this ensures that unwanted chemicals such as carbon and nitrogen do not come into the metals. MAG uses the active gas carbon dioxide as the protective gas, and thus it is also called CO2 welding.

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FORMATS

ABB robot parts maximum dimensions:   900mm x 2000mm    
Migatronic robot parts maximum dimensions:   700mm x 1200mm

 

MATERIALS

Iron
Aluminium
Stainless steel

 

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