Case of Vacuum Coating Processing for Creative Spherical Robot Shell

I. Project Background

II. Difficulties in Film Coating Processing

1. Curved Surface Adaptability: The robot shell is a spherical curved surface with a complex curvature and a multi – component splicing structure. During film coating, it is necessary to ensure that the film material fits closely without wrinkles or bubbles, which places extremely high requirements on the film coating process and mold adaptability.
2. Color Precision: The design requires the restoration of the classic black – and – white color scheme of a football, and the blue decorative area should have bright colors and a natural transition. It is necessary to accurately control the color selection, printing of the film material, and the color presentation during the film coating process to match the brand’s visual standards.
3. Performance Compatibility: It is necessary to ensure that the film coating layer has good wear resistance and weather resistance to withstand scratches and environmental influences during daily use. At the same time, it is necessary to control the thickness of the film layer so as not to affect the original structural accuracy and touch of the robot shell.

III. Jili Solutions

(I) Process Planning

1. Film Material Selection and Pretreatment: A high – quality and environmentally friendly PET film – coating material is selected, which has good flexibility and wear resistance. The film material is pre – treated with tension adjustment and surface cleaning to ensure stable material conditions during film coating and lay a foundation for accurate fitting.
2. Custom – made Mold Design: For the spherical curved surface and component splicing structure, multiple sets of adaptive molds are designed. By simulating the film coating process through 3D modeling, the mold curvature and positioning points are optimized to ensure that the film material can be evenly extended and seamlessly fitted on the curved shell.
3. Step – by – Step Film Coating Process:
   • Base Layer Film Coating: First, the main body of the robot shell is coated with a black – and – white color – matching film material. The vacuum adsorption film – coating technology is adopted to accurately control the temperature, pressure, and adsorption time, so that the film material fits closely to the curved surface and eliminates wrinkles and bubbles.
   • Decorative Layer Film Coating: For the blue decorative area and details such as the number “01”, a high – precision printed film material is selected, and color printing and pattern positioning are completed in advance. Through the local hot – pressing film – coating process, the decorative area is accurately covered to ensure a natural color transition and clear patterns.
4. Post – treatment Strengthening: After the film coating is completed, the edges are finely trimmed to remove excess film material. The ultraviolet curing process is adopted to improve the adhesion between the film coating layer and the shell, enhance the wear – resistant and scratch – resistant performance, and ensure the long – lasting color.

(II) Quality Control

1. Process Monitoring: During the film coating process, an online visual inspection system is used to monitor the film material fit and color uniformity in real – time. The temperature and pressure parameters of key processes (such as vacuum adsorption and hot – pressing film coating) are dynamically recorded and analyzed, and deviations are adjusted in a timely manner to ensure processing consistency.
2. Finished Product Inspection: A multi – angle lighting inspection platform is used to check the flatness, bubbles, and wrinkles of the film – coated surface; a colorimeter is used to accurately measure the color deviation to ensure consistency with the design standards; a wear – resistance test (simulating daily use scratches) is carried out to verify the performance of the film – coating layer. After passing all inspections, a quality inspection report is issued.

IV. Project Achievements