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Small product, large quantities - finishing cherry

9/13/15       
Ben Aroh Member

Hi everyone,

First post here, though I frequent the forums. I recently started a little woodworking company. Things are going great, but I have a finishing question that is outside my experience.

We manufacture a small product out of cherry - see the pictures attached. We make all 50 states, cutting them from cherry panels. Each state has a few magnets embedded in it- so it can hold paper clips, keys, etc. The shapes are fairly small and we stain them to a walnut brown color.

I would love to rub on a gel stain, seal them, glaze them & finish. But a finishing process that complicated is just out of the question- trying to minimize handling of the pieces & keep this operation as efficient as possible.

We are about to ship out an order of 1,600 units- and finishing is quite chore!

Currently we spray on a stain, and topcoat with two coats of urethane. I am in Louisville, and purchase my finishing materials from a small company called Jellico Chemicals.

Although our current finishing schedule is simple and quick, I'm not convinced its the best method. Cherry has its quirks, and some pieces get too blotchy and dark for my liking.

Water base materials have caught my eye. I was almost thinking a water based dye (maybe dipped) - followed by a tinted sanding sealer (to kill some grain for more uniformity) and a water based topcoat.

We are looking for a slightly rustic looking finish. Walnut / mahogany brown color. It needs some durability, because of the embedded magnets.

I would love your advice, b/c I simply do not know the best route to go from here!

Thank you so much,

Ben


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www.arohmade.com

9/14/15       #2: Small product, large quantities - f ...
Jim Member

Have you looked into a tumble finish?

It works great for large batches of small products.

9/14/15       #3: Small product, large quantities - f ...
Ben Aroh Member

Interesting! I hadn't thought of a tumble finish- but I'm concerned the states may actually be too big for that? Most end up around 12" long. Also many states have areas that may be prone to breaking off.

But I will do some research!

I wish I could tumble sand the edges somehow! The CNC leaves a decent edge most of the time- but still requires hand sanding. (at least we are able to edge sand groups of 20 states at a time)


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9/14/15       #4: Small product, large quantities - f ...
Bart

I'm a big fan of WB I've used General Finish products for years. That being said WB stains/dyes will raise the grain which could be a problem when doing large batches. I'd stick to a solvent NGR (non grain raising) type of dye or stain and a dip/spray nitro lacquer finish (urethane seem a bit of overkill). Little or no sanding necessary and a decent finish. Mohawk has all sorts of NGR dyes and stains and lacquers.

9/14/15       #5: Small product, large quantities - f ...
joe

Ben,

As far as the color you should be using a spay stain not a wiping stain.Considering these parts are flat and your spraying a thousand plus pieces you should be looking into a small line spray something like the Cefla Mito K should be something to look into

9/14/15       #6: Small product, large quantities - f ...
Ben Aroh Member

That Mito K machine looks pretty amazing! I contacted them out of curiosity- but I have a feeling we can't afford it just yet. Definitely something for us to keep in mind! I wonder how it would do on the edges?

I do need to switch to a spray "no wipe" stain for color. That will likely be the best alternative. I've never used one actually!

Also, the urethane may be overkill. But I love how quickly it builds. Two coats seems to do the job.

I'll check prices on the Mohawk lacquers, and maybe give one of those a shot too.

9/14/15       #7: Small product, large quantities - f ...
Denny J

You might be a good candidate for a WB UV system. Do a google search for VanTechnologies.

9/16/15       #8: Small product, large quantities - f ...
JeffA

Those look samples look great. The detail is what will kill you, especially those edges. Once they are smooth it should go well. I wouldn't use water based until topcoat. Did you ease the edges? That will help with keeping the cut through's at a minimum. Looks like alot of hand work.

9/16/15       #9: Small product, large quantities - f ...
Ben Aroh Member

Thanks Jeff!
But I'm not quite sure what you mean by cut throughs?

9/17/15       #10: Small product, large quantities - f ...
JeffA

I should have said sealer sand cut through. When you sealer sand a sharp edge, you cut through all the way down to raw wood, taking off the stain and leaving a spot that needs touch up with stain. If the edges are eased or rounded a bit, the cut though's don't happen as much.

11/12/15       #11: Small product, large quantities - f ...
monty

"Splash Stain"!!!!
We use it on chairs, just dip, roll and dry. Easy to use and will work on anything.
Monty


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