Pad printing is used in automotive, medical, electrical and other industries, employing diverse materials to transfer a 2D image onto a 3D object with different sizes and geometries. This work presents a universal fixation system for pad printing of plastic parts (UFSP4) in response to the needs of small companies that cannot afford to invest in the latest technological advances. The UFSP4 comprises two main subsystems: a mechanical support system (i.e., support structure, jig matrix and braking system) and a control system (i.e., an electronic system and an electric-hydraulic system). A relevant feature is the combination of a jig matrix and jig pins to fixate complex workpieces with different sizes. Using finite element analysis (FEA), in the mesh convergence, the total displacement converges to 0.00028781 m after 12,000 elements. The maximum equivalent stress value is 1.22 MPa for the polycarbonate plate in compliance with the safety factor. In a functionality test of the prototype performed in a production environment for one hour, the jigs fixed by the plate did not loosen, maintaining the satisfactory operation of the device. This is consistent with the displacement distribution of the creep analysis and shows the absence of the creep phenomenon. Based on FEA that underpinned the structural health computation of the braking system, the prototype was designed and built, seeking to ensure a reliable and safe device to fixate plastic parts, showing portability, low-cost maintenance and adaptability to the requirements of pad printing of automotive plastic parts.
Keywords: fixture methods; jig matrix; modular fixtures; pad printing; prototype design.