How are Faucets manufactured?
Faucets are fixtures that help in the regulation of water from a pipe. It consists of an orifice that opens and closes and controls the flow of water. Faucets are used in bathrooms and kitchens to make efficient utilization of water. Faucets are made up of the following components:
– Lift rod
– Water inlets
– Mixing Chamber
The faucet production process includes several steps and each step is equally important as the quality of the final product depends on it. We have compiled the list of steps that are involved in producing a faucet. Let’s get straight into it.
Step 1-Raw Materials
Brass is an alloy of copper and zinc that is popularly used for manufacturing faucets because of its property to be resistant to corrosion and hard-water calcification. The components of a faucet can be made up of metals other than copper and zinc. These are received as finished components from other manufacturers.
Step 2-Casting and Moulding
A core is a device that is used in casting and moulding processes. It is used to produce re-entrant angles and cavities in the faucet and once it has served its purpose, it is destroyed to get it out of the piece. It can be costly but it is used to provide details that cannot be integrated into the design without using a core.
The main body of the faucet is obtained either through die-casting or its shape is cut out from high-quality brass rods. In die-casting, brass is melted at high temperatures, approx. 1150°C and is poured into moulds of the desired shape.
This is a computer-controlled process that ensures that all the surfaces of the die-casted product are finished with a high degree of efficiency and smoothness. The passage through which the water will pass is also smoothened using the machining process.
This process is essential to achieve precise surface finishing. To obtain a high-quality product that exudes a shine, the brass surface is polished to technical precision. This is a combination of manual and machine-driven processes. Once the polishing is done, only then can the product be sent for chrome plating.
Step 5-Checking for defects
The next process is electroplating, but before that, the products are checked physically for imperfections like asymmetric lines and curves, polishing errors, and geometrical errors. This ensures that the next process is more efficient.
In this process, first, a base coating of electroplated Nickel is applied to the product. After that, a thin coating of electroplated chromium is applied. The chromium layer makes it durable and corrosion-resistant. After plating, the faucet is installed with various components which is a computerized process. The faucet and the components are stored for a while so that they are set before being sent to the assembly and fitment.
Step 7-Assembly Line
The assembly can involve both manual and automated processes. This process takes place on rotary assembly machines which are precisely controlled. The nozzle, if separate, is installed first. Cartridge and control levers are installed after the nozzle.
The created faucets are then tested rigorously on both water and compressed air. Samples are tested for critical dimensions and durability. Faucets are also required to pass several environmental regulations.
Step 9-Research & Development
Faucet manufacturers continue to add value and quality to meet the ever-changing demands in the market. R&D is an ongoing process and helps to make the whole manufacturing process efficient.
Step 10- Recycling
The various processes involved in the manufacturing of faucets may produce waste materials that must be recycled or effectively disposed of. Machining and forging processes may generate waste in the form of scrap metal that is recycled.
The final process in the production of faucets is transportation. After the manufactured faucets pass all the trials, they are sent out into the market.