How Professional Trophies are mare.
Six Steps in making the perfect Trophy.
- Different parts of the trophy are produced in different ways. The components are either moulded using steel dies, or extruded through a die using pressure and some heat. Most of the parts, including the risers, base, and figurine, are injection moulded. To mould a plastic part, an automatic feeder system is fed a continuous stream of plastic pellets. The machines are loaded with many millions of pounds of plastic pellets each year to make various parts of the trophy.
- The moulding machine is fitted with very expensive specially designed steel dies. The machines melt the pellets into a liquid and, using extraordinary pressure against the dies, form the trophy bases, risers, and figures. The dies form between up to 12 components of a single design per cycle (the number varies on the size of the component). The machines are operated by a worker who oversees the production. A metal stud is inserted into the body of each of these figures to ensure the strength of this component as parts of the figure (ankle, wrist, neck) may be of thin plastic and subject to breakage. One of the largest manufactories of trophy parts runs 40 such moulding machines six days a week, three shifts a day.
- Bases must then be filled with gypsum to give the base a proper weight without using too much brittle plastic. Figurines that are not to be given a silver-or gold-tone finish are essentially done and are pushed through the machine and out, ready to be assembled at the retailers.
- Figures that are to receive a metallized finish are put operator onto the hot stamp foil machine. The plastic figures are washed with a top coat, then metal foil (which comes in 54-in (1.4-m) wide rolls and comes off in linear feet) is heated and pressed onto them. Those parts that are to be coloured as well as metallized are decorated in a similar fashion. The figures are now moved away from the machine, ready to be boxed and shipped to assemblers.
- The columns are form from plastic pellets that go into a machine, melted, then forced (extruded) through a formed die. As they go through the die they're cut to the required length. These, too, then move away from the machine ready for boxing. made of extruded plastic
- The components are automatically bagged and boxed by a machine and ready for shipment to the assemblers.
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