The principles and standard processes of texturing are as follows,
Remove oil and dust from the mold to get clean surface.
Tapes and paint are used to mask the sides and bottom of the mold that are not to be textured.
The acid-resistant wax with base pattern is transferred to the mold surface.
The mold surface is etched in by etchant. This corrosion removes the metal and creates an uneven surface creating pattern.
Blasting with alumina and glass beads. This is also to adjust gloss level.
Principles of texturing
Various patterns such as sand, rock, wood, leather and geometric grains can be reproduced on mold surfaces by texturing. In order to reproduce a realistic-looking grain, "printing" at step 3 and the "etching "at 4 are repeated. The same principale is applied to any patterns to reproduce. The each process is shown in the following cross-sectional diagram of a mold.
By repeating the printing and etching as described above, a richly expressive texture pattern with various ups and downs are created. A simple texture is created with 1 step (printing and etching). There are some patterns that require this step is repeated 10 times or more.
About 80% of the entire process of texturing is done by hands. The printing is particularly time-consuming and requires a great deal of skills, experiences and attention to detail.
The repetitive printing and etching are a point where texturing houses compete with each other in terms of technology, and is an area where they can show their skills and experiences.
- Metal removed at the 1st etching
- Metal removed at the 2nd etching
- Metal removed at the 3rd etching
Cross-section of the mold