How WATEROPERATE make taps from order to production?

The production process of WATEROPERATE faucets incorporates a blend of automation and manual craftsmanship. In essence, the key stages include core building, casting, sawing, machining, grinding, polishing, plating, assembly, and quality testing. Nevertheless, a significant amount of groundwork is conducted prior to these stages: initial product design, followed by computer-simulated production, after which casting has been tested and adjusted until it is perfected. WATEROPERATE develops all the necessary tools, shell molds, and core boxes internally for the casting process.

Process:

• Mold making: the pivotal production processes are crucial in transforming abstract concepts into production, marking the initial phases of part making. The primary manufacturing techniques encompass casting, hot forging, injection molding, die casting, sintering, and drawing. Throughout this stage, a minimum of two out of the three specified types of inspections are carried out, contingent upon the manufacturing procedure at hand. Across the board, assessments pertaining to raw materials and dimensional accuracy are administered, while assessments of performance metrics are executed solely as necessitated by the particular processing method.
• Core foundry: Manufacturing, the fundamental component that reigns supreme is brass, an essential material utilized in casting the faucet body. At the heart of this intricate production process lies the core, playing an important role in creating water passageways within the faucet body during the casting phase. This solid core is meticulously crafted from a blend of fine sand and a potent hardening agent, undergoing a transformation through a heating process within a specialized core box.
• Gravity Casting: The mould is sealed and placed in the blazing hot casting chamber of the casting furnace. Three tons of molten brass flow from the casting furnace into shell moulds. The core maintains waterways open inside the mould, to which technical components are installed and through which water flows through the faucet. During casting, the shell mould is dipped into a water and graphite solution. The caster (the person responsible for casting) places the cores inside the mould and removes any loose sand from the shell mould using compressed air.
• CNC Machining: The milling and drilling holes for the rough brass shell will be finished by our CNC machine, it produces high-accuracy parts with excellent physical properties directly from our CAD drawing file. Due to the high level of automation, WATEROPERAT provide the price-competitive and high-accuracy for both one-off custom taps and medium-volume productions.
• Polishing: 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. Faucet bodies are then placed on a conveyor belt, which moves them through automated machining, grinding and polishing processes. The initially produced rough surface is made smooth during a complicated grinding process. Once the polishing is done, only then can the product be sent for chrome plating.
• Surface treatment: The Kitchen and Bath taps and shower mixer industry relies heavily on 4 main finish types to achieve the desired look for consumers and designers alike. PVD, Electroplating, Polished Chrome and Powder Coat methods each contain merits and demerits with respect to appearance and durability.  In the overview below, each one of these finish types are explained in a bit more detail when used for taps and shower mixer. In order to meet consumer demands within our extensive bath and kitchen collections, WATEROPERATE leverages a comprehensive array of finish technologies. PVD finishes tend to be the most versatile and durable, this technology makes up the majority of our high quality special finish products. Our steadfast commitment to investing in this cutting-edge technology is underscored by its superior surface resilience and diverse palette of colors and textures.
• Assembly: The assembly can involve both manual and automated processes. This process takes place on rotary assembly machines which are precisely controlled. Components and any electronics that are significant, especially in more advanced water fixtures, are installed inside faucets during assembly. WATEROPERATE faucets are assembled by hand and automatically, while the final inspection and quality control are always manual processes.
• Quality Testing: The created faucets are then tested rigorously on both water and compressed air.  WATEROPERATE quality testing team will take the main components of taps or shower from the production line at random , testing the resistance to corrosion by salt spray test machine. Samples are tested for critical dimensions and durability. Faucets are also required to pass several environmental regulations. After assembly, the taps are meticulously packaged, protecting them from damage during transportation and displaying brand information and product details.

The brass tap manufacturing process is a testament to precision, craftsmanship, and attention to detail. From the initial raw material selection to the final assembly and packaging, every stage is meticulously executed to deliver high-quality taps that combine aesthetic appeal with superior functionality. The result is a range of stunning brass taps that homeowners can rely on for years to come, adding a touch of elegance to their bathrooms and kitchens.