The problem was that "laser processing would be prohibitively expensive."
From the designer in charge of the store's interior design:
I once received an inquiry from someone who wanted to have a curtain made from metal.
The client wanted to have their graphic design printed on metal panels and installed in their store.
The first method the person considered was to use laser processing to create holes for the pattern.
When we actually got quotes, we realized that it wouldn't fit within our planned budget.
The more complex the design, the longer the laser processing takes.
While laser processing can handle intricate patterns and large areas,
The cost increases in proportion to the length and time spent cutting.
As in this case,
When incorporating a design created by an illustrator into a large panel set measuring 2800mm in height and 8000mm in length,
The total length of the patterned lines is quite long.
Since each line is traced with a laser, the processing time and cost will increase proportionally.
It is unavoidable due to the nature of the manufacturing process.
If you decide on the processing method based solely on budget before making a decision, it will be very difficult to go back and change it.
When the estimate exceeds the budget, we simplify the design itself to reduce costs.
This is one way we sometimes proceed.
If you later remove a pattern that was created with meaning as part of the store's interior design,
The worldview that I originally wanted to convey will become diluted.
In projects with fixed deadlines, there isn't enough time to reconsider the processing methods.
It's also common for projects to proceed with compromised specifications.
There are several methods for drilling holes besides lasers.
Lasers aren't the only way to create patterned holes in metal panels.
The method we proposed this time is called "design punching."
Applying the technology of punching metal, which uses a mold to punch holes in one go,
Based on the illustrator's design data, we create a die to cut out the pattern.
Once the mold is created, the subsequent punching process can be completed in a short amount of time.
Since the cost is mainly due to the creation of the mold rather than the total length of the lines, the more complex the pattern and the larger the area, the higher the cost.
The cost difference compared to laser treatment can become more apparent.
Of course, for small-volume, one-off processing, the mold cost will be higher.
Laser treatment may be a better option for some people.
We look at the quantity and the complexity of the design to determine which is more suitable.
It was made from 1.5mm thick aluminum, finished with a combination of R-bending and painting.
In this project, after creating a pattern on a 1.5mm thick aluminum panel using design punching,
We added an R-bend to the fabric to create a wavy, curtain-like effect.
Because of the large size, to prevent the pattern from shifting at the joints between the boards,
We have added a positioning step.
The finish is baked enamel paint.
The color was mixed from a color sample to match the interior color of the store.
We created a sample and compared it to the actual colors used on-site before proceeding with the final production.
The mounting brackets are manufactured using a lathe and installed in the local stores.
The construction period was one month.
You can start by asking, "Can this be done with a laser?" and we'll discuss it with you.
MACHICOCO is a company based in Higashi-Osaka.
We provide project management services to bring products and equipment to life in collaboration with engineers at local factories.
We don't own large-scale facilities in-house; we start by combining processing methods according to the design intent.
We handle everything from manufacturing and finishing to delivery to the site.
You are welcome to contact us with the premise that "we want to do it using this processing method."
After discussing the design intent, quantity, and construction period, we will proceed with laser cutting, punching, sheet metal processing, etc.
We will suggest the most suitable method from among several processing options.
If you have illustrator data, hand-drawn sketches, or reference photos,
We can then begin our review based on that.
Even without drawings,
We can begin discussing manufacturing methods based on your design data or sketches.
