Metal Buttons Making Process.

 Metal buttons are manufactured using following process.

1) Material Selection.
Material Selection in button making is an important factor. Metal buttons are one of the most popular
buttons due to their surface finish, durability and decorative function. Based on the manufacturing
materials, metal buttons can be further grouped into:

1.1) Zinc Alloy Buttons.

1.2) Brass Alloy Buttons

Zinc alloy buttons and brass buttons are two of the most commonly available metal buttons on the
market. Stainless steel buttons are also popular due to their lower chances rusting as compared with the
zinc alloy buttons and brass buttons. Aluminum buttons that can achieve special effects are also
available on the market. However, iron buttons whose surface is susceptible to rusting and corruption
are seldom used.

The most Common used metal buttons are of Zinc Alloy buttons and
Brass Alloy buttons.

1.1) Zinc Alloy Buttons

Zinc alloy buttons are generally manufactured out of 5# zinc alloy (ZAMAK 5),
which is majorly comprised of zinc and aluminum. These buttons will go
through the polishing treatment following the die-casting process, which
removes the burr along the button edges or in the holes and takes care of the
surface that is not smooth before they are subjected to the electroplating
process.

2) Button Manufacturing Processes

There are two type button manufacturing Processes.
2.1) Die Casting Process.
2.2) Stamping Process.

2.1) Die Casting Process.

Die casting is a manufacturing process that can
produce geometrically complex metal parts through
the use of reusable molds, called dies. The die casting
process involves the use of a furnace, metal, die
casting machine, and die. The metal, typically a non-
ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die
casting machine. There are two main types of die casting machines - hot chamber machines (used for
alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with
high melting temperatures, such as aluminum).
Production process: making mould – die casting – trimming burrs – polishing – surface treatment –
assembly – quality inspection – packaging and delivery.

2.2) Stamping Process.

Stamping process takes advantage of the plastic deformation and elastic ability of some metal materials
like copper, iron and aluminum. Metal materials will be transformed into the required shape by press
machine through pressing and punching, the state of which will not be changed during the whole
manufacturing process.

Production process: making mould – cutting raw material into strips – stamping – surface treatment –
assembly – quality inspection – packaging and delivery.

3) Alloy Button Making Procedure via Die Casting.

Step No 1: Set the dice (male part and female part) on Die Casting Machine dice holder by nut bolt and
mold setting instrument.

Step No 2: Keep the Zinc bar/ Brass Bar to the heating place of the machine. Then heat the machine at
900 degree centigrade electrically. The Zn Bar will melt at that temperature.

Step No 3: When the machine start both the part of dice closed and a nozzle push push melted Zn to
inside the dice with high pressure. The melted metal is poured into dice runner and gates.
The cycle time for pouring metal into dice depends on how many core are made in dice, and
thickness of button. Usually, the cycle time is 10 to 15 seconds. Each dice have multiple
core depending on Alloy Button sizes.

Step No 4: Now need to check the button quality after taking the button from separator/roller machine.
Automatic button sorting machine can be used for quality check or we can check the quality
manually.

Step No 5: Button coloring: After quality checking we need to send the button for electroplating bath as per
buyer require color.

Step No 6: After electroplating, again the quality of the alloy buttons is inspected following the standard
sample.

Step No 7: The inspected buttons are weighted and packed into poly bags. These packed alloy buttons
are ready for shipment or supply.