2. Company
Profile
From concept to reality with
MASTARS
Established in 1998, Mastars now has expert manufacturing facilities for the mass production of a wide variety of plastic & metal
parts by means of injection moulding and tooling, die casting and tooling, sheet metal stamping & laser cutting, CNC machining,
Metal Injection Moulding, plastic and metal extrusion. Fabrication, assembly and secondary operation machining can also be
undertaken and a wide variety surface treatment finishes is available. We also offer an extensive CNC prototyping service
producing a vast array of parts in production intent metals and plastics. Where required we can also use more conventional
prototyping technologies to produce SLS, SLA, SLW and vacuum cast items.
In line with our corporate philosophy customers benefit from our unique blend of quality, reasonable cost, integrated services
and flexibility. Our ability to achieve customers’ targets within a very short turnaround gives them a strong competitive edge.
4. Design & Engineering
Prototyping
Mould manufacturing
Injection moulding
CNC Machining
Pressure die casting
Metal injection moulding
Plastic & metal extrusion
Metal pressings
Assembly
Painting
Chrome plating
Anodising
Vacuum metalisation
WHAT
WE DO
5. Design & Engineering
Design & Engineering
Our tooling design team has highly skilled expert engineers with many years experience of designing injection mould tools to produce top quality
parts in all thermoplastics and for most industries.
We have in house Moldflow simulation software to optimise tool design ,manufacture, gating, cooling and moulding parameters.
We believe in proactive communications to minimise problems occurring both during design and manufacturing thus ensuring our customers
expectations and needs are fully achieved.
6. Prototyping
We utilise the latest software programmes, sophisticated CNC machines, modern measuring equipment and highly
skilled technicians to produce over ONE MILLION prototype parts each year!
These can vary in size from a few millimetres to complex components such as automotive instrument panels. A wide
variety of plastic and metal billet is always in stock to suit the many needs of customers. When required we can also
quickly source more exotic materials for special projects. The majority of Mastars prototypes are produced by CNC
thus ensuring accuracy equal to, or better than, injection moulding and allows customers to have their prototypes
manufactured in production intent materials. We can also offer SLA, SLS, SLW (selective laser welding of metals) and
vacuum casting.
Before commencing manufacture of any components, our dedicated Account Managers and Project Engineers will
discuss with customers the required performance of the prototype parts in order to ensure that only the most suitable
materials, method of producing, finishing and shipping are employed.
8. MouldManufacturing
Mastars utilise the latest design software to meet the requirements of complex part geometry and manufacture tools of up to 15T that produce parts for a wide range of industries
includingAutomotive, Medical,Aerospace, Scientific, Domestic appliance and Leisure.
CAD/CAM work stations are integrated directly with our high speed CNC Machining centres to ensure high accuracy, top quality and repeatability. Our toolmaking capacity has
recently been enlarged and augmented with latest 5 axis CNC capability as well as 5 of the most up to date EDM machines available.
High volume production mould tools are constructed using only the best quality materials to ensure a long service life for the mould tool and great value for money.
9. Mastars also produce tools to suit low volume and prototype requirements. Some of these tools may share a
mould base and/or have hand removable inserts.
We have in house Moldflow and tool trialing, ultrasonic polishing and can also undertake very cost effective
cavity finishing to a wide range of industry standard textures.
Our service includes careful initial discussions to ensure the customer will achieve their expectations and
aims coupled with regular updates of the tooling manufacturing progress.
10. Injection Moulding
Experience in producing top quality parts in all general and most engineering thermoplastic
polymers including Ultem, PEEK and specially compounded polymers for conductivity and
RF screening and other specialised requirements.
40 injection moulding machines ranging from 50T to 650T clamping force. 20 machines with
full robotics.
24/7 operation.
Flexibility to manage both small volume and high volume production batch sizes.
11. CNC Machining
Mastars provides a wide range of specialist CNC Routing
services both large and small in many different industries.
We offer 5-axis machining of materials, metal spraying and
hard coating for the film, marine, construction and composite
industries.
We use the very latest in CAD/CAM software, and are able
to work with most industry-standard 3d files. Our machinery
is accurate tovery tight tolerances, ensuring the closest
possible match between specifications and finished product.
12. Pressure Die Casting
Mastars' pressure die casting facility has in house tooling capability that can produce moulds for parts that can weigh up to 2.5KGS and measure up to 500x500x250mm.
We have 10 die casting machines ranging in clamp force from 80T to 630T and casting materials in common use are aluminum (ADC10/12 and A380 typically) and zinc (3#/5#).
Cast parts can also have extensive second operations in Mastars own machining facilities as well as a wide range of cosmetic finishing including powder coating, spray painting,
anodizing, polishing and plating.
Part quantities may vary from 50 or 100 off prototype parts to many thousands of mass production requirements – all of which will be produced with the care and precision we
apply to all of our projects.
13. MIM
Metal Injection Moulding (MIM) combines the advantages of the large degree of design freedom that comes with
plastic injection moulding with the excellent mechanical and thermal characteristics of metallic materials. Now a
well matured and trusted process it is capable of producing high-precisionmetal components for a wide variety of
industries including electronics, mobile phones, medical and scientific equipment.A good range of metals is
available.
Components produced using the Metal Injection Moulding process are free of residue and attain density values of
almost 100%.They have similar characteristics to machined components.The MIM process is environmentally-friendly
and does not waste resources as the granulates are recycled. Because multi impression moulds can be used it is
an ideal way of producing large volumes of low cost, small, complex geometry, precision parts such as SIM card
holders, small gears and spectacle hinges.
14. Quality Control
DATA ISTHETRUTH
We believe that a supplier has to supply customers not only with high
quality product but high quality overall service as well. At Mastars we
believe this starts with receipt and expert evaluation of requirements,
speedy response to requests for quotations and to any subsequent
queries followed by a controlled and integrated manufacturing process
and a fast reliable delivery service. Our dynamic feedback loop linking
QA/QC, manufacturing and production, results in higher throughput,
lowered rejection rates and consistent quality.
We aim to catch any problems and resolve them before they can grow.
We are very familiar with all international product standards and our
in-house experts implement strict procedures accordingly.
Mastars is constantly seeking development through quality improvement
and we currently have the following approvals.
ISO 14001 – 2004
ISO 9001 - 2008
16. We have succeeded in becoming a top integrated OEM manufacturer. But we never stop.
We are committed to excellence at all levels of our global operations.
We are fueled with a passion to deliver exciting solutions – with an eye on safety,
sustainability, cost and comfort – that will satisfy consumer desire for exciting new products,
now and in the future.
