How Bar Mats Are Made: A Step-by-Step Guide
Designing the Mold Artwork
The first step in the production of custom bar mats is based on the client’s flat design draft. We generate a mold artwork from this design. The mold is typically made of aluminum, known for its durability and precision.
Mold Production and Sandblast
Once the mold artwork is finalized, we proceed to manufacture the mold. After its production, the mold undergoes a sandblasting process. This step ensures the surface of the mold is smooth, which is crucial for the quality of the bar mats.
Dispensing Liquid Material
The production process begins with the application of various colors of liquid material. A specialized liquid dispensing machine is used to accurately place the colors onto designated areas of the mold, ensuring each color is in its correct position.
Heating and Curing
The mold, now filled with the liquid material, is placed in an oven. The heating process allows the material to cure and solidify,forming the initial design of the bar mat.
Removing Excess Material and Inspection
After heating, the mold is removed from the oven. We then inspect the material to ensure it has solidified properly and maintained cleanliness in other areas. Any excess material is carefully cleaned off.
Adding the Base Material
The next step involves pouring the base material into the mold. We make sure the liquid is evenly distributed by tapping the mold.This step is crucial for the structural integrity of the bar mat.
Vacuuming and Second Heating
The filled mold is placed in a vacuum machine to remove any air bubbles, ensuring a smooth finish. It is then heated again to further solidify the material.
Cooling and Final Extraction
Once the material is fully cured, the mold is moved to a cooling trough to bring it down to a safe temperature. Workers then carefully extract the finished bar mat from the mold.
Final Inspection and Trimming
The last step is a thorough inspection and trimming of the bar mat to ensure it meets our quality standards. This includes checking for any imperfections and making necessary adjustments.
