Let us take an Iphone 4 clear screen protector manufacturing process as an example.
1 Choose the screen protector film rolls.
There are several kinds of screen protector film rolls or sheet,such as ultra-clear,matter,privacy.., and even the same kind of protector film have different quality,according to the manufacturer's bacic material,technology,and equipments.After confirm one protector sample, we purchase screen protector film rolls and commonly, it is 200m*1040mm/roll.
2 Laminate the PE film in the surface of the protect film rolls and slit the rolls into smaller width rolls
There are 3 layers which consist of the protect film.To avoid the top layer to be hurt in the later produce process, we lamilate a thin PE film in the surface of the screen protector roll in the big laminator,,while re-rolling the 3 layer PET film.It is hight technical work,because you have to make the re-rolls without dust,bubble in it.
Before we put the protector film into the die cutting machine, we need to slit the 200m length roll in to smaller width roll.For Iphone 4, we need 115mm*200m small roll(260mm*200m roll for Ipad 2,124mm*200m for iPhone 5,145mm*200m for I9220). And most of times, lamilating and slitting can be completed in one single machine at the same time.
Commonly the the lamilationg & Slitting machine can do the 2 job at the same time
Laminating and Slitting Machine video
3 Load the kinfe die into the die cutting machine
To make the screen protector,we need the metal knife die, and one knife die only cutting one shape of screen protector.Each kinfe die can work about 50,000,000 times, and then you have to replace it, otherwise, you will get imperfect screen protector. But it is good, the mould is not expensive.such as an iPhone 4 front knife die is about 15USD.
4 Load the slitted and lamilated roll into the die cutting machine.
What ever the handle die cutting machine, auto die cutting machine, or the digital die cutting machine,the operator have to adjust the 115mm*200m in the right place when infeeding and outfeeding the screen protector roll(note:the lamilated PE film side should be setted in the bottom),then adjust the cutting depth only for the top 3 layers.And make some test cutting, check the screen protector quality, and readjust the machine .if everything is ok,then start the machine and make the screen protector in big qty..
Digital Die Cutting Machine video
5 Packing
The workers pick up the cutted 3 layer screen protectors, if need make customer printing, we can make screen printing in 1,2 or 3 colors. and put the stickers in the corner in the first layer and third layer. then put it into the small transparence polybag. Whereafter wrap it with the printing cardboard,then put it into a big polybag.
Later you can buy the Iphone 4 clear screen protector in the market.
Though FeYong Digital is mainly manufacture the 3 layer screen protector rolls,but we also can offer our clients the completed screen protector manufacturing process consult.
Questions:
1 Can I use the laser cutting machine or plotter to cut the rolls?
Yes, you can, but the cutting speed is too slow for the laser cutting machine. And plotter only can cut lined screen protector, instead of doing complicated jobs.
2 Your rolls is 200m length and 1040 width, can I have smaller width or smaller length rolls?
We can offer you customer width rolls, such as 110mm*200m,, 50cm*200m, but the buyer have to buy the rest length rolls. It is impossible to offer you smaller length rolls. All rolls are only 200m.
3 For the beginning, I do not want invest too much, and buy the lamination & slit machine, do you sell us the laminated and slitted rolls?
Yes, we can, and we will charge it a little
4 Should I only buy the knife die only from you? And how much time to do the knife die?
No, you can buy the knife die anywhere. And it only cost 1 days to finished the knife die.