Our Process
The Methodology –
Creation of a piece of jewellery requires several steps. Firstly ,the design selection is done either by the buyers or by us keeping in mind the trends both for the exports and local market .A number of hand drawings are done by our designers which are then finalized and given for development and production.
Hand drawing designs
Step 1 – Design Creation – CAD (Computer Aided Designing) is now the latest method for designing the jewellery with high precision. The latest technology is used to design the products. Once the designing is done the product is made ready to be printed by a 3D printer. CAM (Computer Aided Manufacturing) is then used to produce the sample in resin. The resin is cleaned and matched with the required design and finally finished.
Computer Aided Designing and 3D Printing
Step 2 – Rubber Mould Creation or Direct printing – This resin is then placed in a liquid rubber which is vulcanized to produce moulds .It can then be reproduced with high accuracy. These rubber moulds are cut with precision to make accurate impression of the resin pieces. At times ,these pieces are directly made into gold for one of a kind handmade jewellery.
Step 4 – Investment and Casting – The wax tree is put into a perforated jar which is packed all around . An investment mixture is prepared by vacuuming the slurry prepared by a special kind of cement.The investment mixture is then poured in into the jar within a specific time period.This process is called investment. The invested tree is baked in the oven at a temperature of 200°C – 700°C which is controlled by the Kilnminder. The process takes place overnight so it is ready the very next day. The baking causes the wax to melt and vaporise and the cement is left with impression of jewellery.
Pure gold is melted along with alloys to prepare the various gold purities as 14k and 18k .We use different alloys to give different colours of gold as white, yellow and pink.
Step 5 – Filing and Handwork – The casted items are cut from the tree and joined together using laser soldering process that provides precision soldering upto 0.2mm. Laser soldering machine provides soldering with very high precision and thus helps us in achieving better quality finish. We develop a lot of unique pieces which involve a lot of handwork by the craftsmen. These one of a kind pieces are made as per customer requirements.
Step 7 – Polishing – Filed and soldered pieces are then polished to smoothen out all the rough surfaces. We use different machines and hand polishing to achieve high quality finish.
Step 8 – Assortment, Sorting and Setting – The polished pieces undergo inspection and then given for sorting the right sizes of stones which are to be set into them. Diamonds and colour stones are sorted according to the sizes required in the mountings. We have installed microscopes for settings involving very small stones.
Step 9 – Finishing and Final Polishing – Once all the stones are set the goods are sent for quality check and polished again.
Step 10 – Quality Check and Dispatch – At Kays, we believe in maintaining the highest standards of quality control. To ensure strict quality control, checks are performed at each stage of the manufacturing process. A final inspection of goods is performed right before dispatch
