Secondary Processes

Secondary, or post processes in manufacturing are commonly noted as value-adds because they are increasing the value of a part after the initial manufacturing process by refining or enhancing certain part properties further.  There are many different techniques used in the rapid manufacturing environment to help provide unique solutions for you parts. In the following section we’ll showcase the common secondary manufacturing processes that we provide alongside some critical information to be considered for each.

Insert Assembly

Adding inserts to plastic parts is a common practice for our assembly team. There are many methods for applying these inserts, and understanding your options before kickoff is crucial to eliminating assembly bottlenecks and reducing costs. We’ve worked on thousands of projects and learned thousands of lessons so you don’t have to – were here to guide you through it all!

Press Fit Inserts

Press fit inserts rely on an interference fit as the holding mechanism, making them a simple and effective option for low-volume parts where materials are sensitive to heat and consistency is key.

Heat Stake Inserts

Heat stake inserts are installed by quickly transferring heat to the insert, allowing it to be easily placed into thermoplastic parts like a hot knife through butter! The melted plastic, combined with common knurled features, creates excellent torque resistance and high pull-out strength. This is a great option for low-volume parts or when multiple types of inserts are needed in the same part.

Ultrasonic Welding (USW) Inserts

When a large number of inserts (e.g., 10 or more) are required on the same part plane, ultrasonic welding is an efficient solution. By creating a fixture or “horn,” the process can be optimized for precision and speed.

Overmold Inserts

Placing inserts directly into the injection mold prior to molding is often the best-case scenario for strength and cost-effectiveness. However, this method may not be ideal in cases where reworking misplaced inserts is necessary, as corrections can be more challenging.

Ultrasonic welding

Ultrasonic welding is an efficient way to join plastic components—or even plastic to metal—without the need for adhesives, or mechanical fasteners. Through high-frequency vibrations, this process creates a strong seamless bonds in seconds. Here’s how it works: a vibrating tool (or "horn") contacts the plastic parts, generating heat through friction to melt and fuse into one homogenous part.

This technique is versatile and quite adaptable. Whether you need a simple plastic-to-plastic weld or a more complex assembly. Some plastics respond better to ultrasonic welding than others; generally, stiffer materials are easier to work with, while high-melt plastics may require more energy.

Our Ultrasonic Welding Guide can help you find the right solution for your needs, listing common plastic grades and their compatibility with each welding style.Energy Directors – The design of energy directors is critical to achieving the seal you need. Joint design plays a key role in ensuring a proper seal, and factors like resin type and desired seal properties will guide the design of these energy-directing features.

Post Machining: The Solution for Perfect Precision

No manufacturing process hits perfect tolerances straight out of the gate. While 3D printing and urethane casting often works wonders for fast turnarounds, their standard tolerances might not meet your tightest requirements. That’s where post machining comes in—a game-changer for achieving pin point precision and elevating your parts to meet exact specs.

Whether it’s fine-tuning a complex geometry or dialing in tolerances that other methods can’t touch, we’ve got you covered. It’s precise, efficient, and the ultimate go-to when perfection is non-negotiable.

Why Choose Post Machining?

• Ultra-High Tolerances: Achieve the finest tolerances where precision is critical.
• Low Volume Solutions: Perfect for prototypes or specialized production runs.
• Unique Gating Adjustments: Overcome challenging geometries with ease.
• No Draft Allowances Needed: Bypass design restrictions for fully optimized parts.

Powder Coating – This unique two-step process starts by giving the metal part an electric charge, which attracts a dry powder to its surface. It’s then baked in an oven to create a tough, uniform coating. Unlike liquid paint, powder coating allows for a thicker, sag-free layer, making it an excellent choice for a durable, corrosion-resistant finish.

When designing part with powder coating keep in mind Powder coating adds about .004” to .010” (0.102mm to 0.254mm) to your part’s thickness, so remember to factor this in for tight clearances or small holes in your design.

Electroplating vs. Vacuum Metallizing: What You Need to Know

Choosing the right surface treatment can feel overwhelming, but we’re here to simplify it for you. Electroplating and vacuum metallizing are two versatile processes that deliver unique benefits depending on your goals. Let’s break them down to help you decide.

Electroplating: Built for Durability and Performance

Electroplating applies a thin metal layer to a surface using an electric current. This process is all about improving durability, protecting against corrosion, and enhancing electrical conductivity.

BACKGROUND

An automotive beta build for a local EV manufacture was scheduled, but one team faced delays with the critical frame design, essential for assembly, as other teams relied on these key features to progress toward their own milestones. Our solution allowed all small component teams to proceed in parallel while allowing the foundational frame team to iterate freely without becoming a bottle neck.

Key Advantages

• Boosts wear and corrosion resistance
• Improves electrical performance (like EMI shielding)
• Adds a protective barrier for harsh environments

Electroplating is often used in industries where precision and performance are critical, like electronics, aerospace, and automotive manufacturing.

Vacuum Metallizing: Thin, Precise, and Versatile

Vacuum metallizing, or vacuum deposition, vaporizes metal in a vacuum chamber to coat a substrate. The result is a clean, lightweight coating that’s highly reflective and functional.

Key Advantages

• Safer and more cost-effective than chromium plating
• Enhances optical and barrier properties
• Creates durable, hard coatings with excellent heat resistance

This process is a go-to for applications like packaging, lighting, and reflective surfaces in industries ranging from automotive to aerospace.

Pad Printing: Precision Marking for Surfaces

Pad printing is a tried-and-true method for transferring 2D images onto 3D objects with precision. Here’s how it works: an etched plate holding the desired image is filled with ink. A transfer pad picks up the ink from the plate and presses it onto the surface of your part, leaving a crisp, detailed image behind.

This technique shines on irregular shapes or surfaces, making it a go-to solution for adding fine details. With quick-drying inks, you avoid common issues like smearing or dripping, keeping the process clean and efficient. However, because pads and inks are sensitive to airborne contaminants, rigorous quality control is key to maintaining consistency.

Why Choose Pad Printing?

• Handles single-color or multi-color designs
• Works on a variety of plastics
• Ideal for detailed graphics or lettering
• Perfect for applications like toys, sporting goods, electronics, and appliance housings

With process automation and versatile equipment—including ink cups, shuttles, and transfer pads—pad printing delivers high-quality results even at higher volumes. Whether it’s a simple design or a multi-color masterpiece, this method gets the job done with accuracy and efficiency.