The Application
A manufacturer of IPL hair removal equipment required a bespoke PTFE component to provide electrical insulation around internal componentry and terminals within the device.
The finished component measured 67 mm long x 27 mm wide x 12.5 mm deep and was manufactured from 1 mm thick PTFE sheet.
PTFE was selected for its electrical insulation properties, making it suitable for protecting the surrounding components within the device.
The Challenge
The part needed to closely follow the shape of the component it was designed to insulate, but also needed to be supplied flat so that it could be formed around the componentry during the customer’s manufacturing process.
The design also incorporated terminals that required additional coverage.
This meant the component needed more than a straightforward punched profile. It also required precisely positioned score lines and formed features.
The Solution
Adtech punched the 1 mm PTFE sheet to the required external profile before adding score lines in the correct positions.
These score lines allowed the flat component to be folded into its final three-dimensional shape during assembly.
Dimples were also formed into the PTFE so that the terminals on the device could be covered as part of the finished insulation component.
The Result
The customer received a bespoke PTFE insulation component supplied flat and ready to be formed around the device during manufacture.
The combination of punching, scoring and forming allowed a relatively complex insulating profile to be produced from a single piece of PTFE sheet.
