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Plastic frames are available in a wide range colours and styles, in forms of subtle and dramatic. They are generally more casual in appearance and less expensive than metal frames. Plastics used in frames are classified in two major categories. They are cellulose propionate and cellulose acetate. (The trade name for cellulose acetate is zylonite, known as "zyl").
Cellulose propionate frames are created by injection molding, which liquid plastic is injected into a mold under high pressure and heat. The mold is then cooled to produce a solid plastic frame. The production costs are relatively low, but there can be a five-fold difference in cost between one injection molded frame and another.
The advantages of cellulose propionate frames are lightweight and relatively inexpensive. On the other hand, the colours of such frames do not last long and eventually fade and become brittle.
By comparison, cellulose acetate (zyl) frames are made from a solid piece of plastic. Labour is required to mill the frames from solid sheets of the plastic material. Normally, these kind of frames cost more than cellulose propionate frames due to more complicated procedure. Also. this plastic material is more durable and is available with longer lasting finishes.
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Plastic eyewear is made with cellulose acetate (zyl). The whole manufacturing process takes about three to four weeks and is done by hand. First, cut the zyl into small sheets which correspond to the style of frame we want and then we use the pantograph machine to mill out the shape. For some special designs, we use a bevel on the front or back of the frame. After that, we use a special epoxy to glue on the plastic nose-pads and weld the front hinges to the frame with an ultrasonic machine. The next procedure is to use sand paper, files, and a metal plate to touch up all the minor details on each frame. We now have a front frame.
This batch of frames will then go to the “tumblers.” In the tumbler, we use the diamond shaped wood pegs and paste to smooth out all the edges and any scratches that may have occurred in the making of these frames. The front frame is now presentable and ready-to-wear
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The next step is to cut the angle that connects the front to the temples by a special cutting machine. This process ensures that each frame has a 90 degree angle on both sides and the right four-point adjustment. The last stage is to hand-polish each frame to ensure the highest quality of shine. With such fine procedures, plastic zyl frames are called handmade frames.
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