Mold texturing originates with photographic arts. Through the eye of a camera, Custom Etch can capture virtually any image or design. These designs can be altered in any way through the use of either conventional photographic arts or by use of state-of-the-art computer imaging - both offered by Custom Etch! We are able to translate Bitmap, Postscript, TIFF, and even Targa files from: CorelDRAW PageMaker Adobe Illustrator PhotoShop and many others...   Once a useable film is rendered, it is then developed into a photo sensitized lithography plate to be used as a pattern master. The newly developed pattern master will join the library of over 1,000 other custom and standard texture patterns. By applying a wax base material to the master plate, a pattern transfer is created. The transfer is lifted from the master plate using a flexible tissue carrier. This carrier is now ready to be applied to virtually any mold cavity contour. When a mold is received at Custom Etch, our qualified staff of technicians and sales engineers review all drawings and parts to ensure a comprehensive understanding of any and all specific job details. After a thorough cleaning of the entire mold, all areas outside of the molding surface are masked out using a vinyl acid resistant tape. This procedure is repeated in greater detail with close tolerance masking inside the molding area, protecting untextured shutoffs, borders and nominal draft areas. Upon completion and quality inspection of this stage, all masking seams are sealed off with another wax base material to insure that no acid will leak into the protected area. The unmasked areas are then vapor honed. Vapor honing takes place in Custom Etch's 12x24 foot sandblasting containment room. Capable of utilizing all blasting media, a mix of fine silica sand and glass beading is used to satinize the desired texture area to aid in the adherence of the pattern transfer. In the printing stage of the process, the pattern transfer is now applied to the designated texture area. However flexible, the tissue carrier will need to be fit to the cavity contour. The use of multiple pattern transfers will require that the transfers be aligned and joined together. The transfer is now burnished onto the surface, and with the use of a releasing agent, the tissue carrier is removed. All match lines and fitted contours are blended by hand using a liquid acid resistant material. During this stage, Custom Etch calls upon the skilled artistry of our technicians to create a uniform patter transition and blend. After a thorough inspection, the mold is ready to move on to the etching area. Etching is the most critical step in the entire texturing process. Here, several variable and factors are calculated and considered prior to exposing a mold to acid. There are pre-determined etching methods and acid formulas utilized depending upon the type of mold ally, the desired depth of pattern, and size of area or mold to be etched. For example, a mold may either be submersed in an acid bath or hung vertically and sprayed with acid. The type of alloy will determine the proper acid formula to be used. The desired depth is governed by the temperature of the mold and acid combined with the amount of time the mold is exposed to the acid. All of these factors are pre-calculated. Custom Etch divides the calculated etching time by three and stops the etching process twice to measure the depth of the pattern versus the amount of exposure time. This allows our technicians an opportunity to make any adjustments in time or acid formula necessary to maintain consistency and the tightest tolerance level possible. After a very thorough cleaning of the mold, it is now ready to be shipped for production. Custom Etch takes pride in the area of turnkey texture repair. Realizing the importance of getting a damaged mold up and running, Custom Etch has devoted an entire department to repair and refurbishing. Possibly the only texturing facility to employ journeymen tool makers, there is a strong emphasis placed on keeping repair work under one roof and not expending valuable time and effort shipping a damaged mold to and from various vendors to have repairs complete. Another great time saving effort is Custom Etch's in-house mechanical engraving. Molds requiring both texture and engraving can easily be accomplished at one location.