Ancient Egyptians mastered the production of copper-tin alloys in 3000 BC, and at the same time, they discovered that copper-tin alloy plates could be used as mirrors after polishing. Since then the evolution of mirrors began.
In 1508, the Italian glassblowers, the Dal Carlo brothers, developed a practical glass mirror, and in 1843, German scientists invented silver-plated glass mirrors, and in the 1970s, scientists invented aluminum mirrors. And now we use the best quality copper-free silver mirrors.
We all use mirrors every day, different mirrors are made of different materials, so how are mirrors made? Now there are so many smart mirrors with many functions, how are smart mirrors made?
Simple mirrors
The raw material for mirrors is mainly glass, and to make mirrors you first need to burn glass. The raw materials of glass: sea sand, quartz sandstone powder, soda ash, dolomite, etc., are prepared in a certain proportion and poured into the melting kiln. After melting at a temperature of 1300°C, the molten glass liquid is poured into the model. After the glass is molded, it is cut, polished, and so on.
The most popular mirrors on the market now are aluminum and silver mirrors(smart mirrors are not included), and next, we will focus on how to make the best mirror on the market, the copper-free silver mirror.
As we all know, ordinary silver mirrors in the production process will be plated after the silver reflective layer, which will add a layer of copper to protect them. However, copper is a heavy metal element, which will have an impact on the environment. As a result, a new environmentally friendly way has appeared – the use of high-tech technology, the use of palladium chloride instead of copper, and the production of copper-free silver mirrors.
First, we rinse the glass with heated distilled water, after which we start silver plating. Since there is no way for the silver itself to adhere directly to the surface of the glass, factory-made mirrors are first sprayed on flat glass with a tiny amount of tin chloride solution, which creates a tin ion-sensitized layer on the surface. The silver here is not silver in the traditional sense of the word we use silver nitrate solution, and the reducing solution is mixed thoroughly and then sprayed on the flat glass attached to the tin chloride solution. After a few seconds, the reduced silver precipitates on the surface of the glass plate and gradually deposits and hardens to form a reflective layer with a silver film.
Immediately after this, we begin to add a protective layer to the silver plating. We start with a layer of palladium chloride, then the mirror passes through a curtain coating machine, where the first layer of protective lacquer is evenly applied and immediately dried in an oven at 99°C. It takes only 105 seconds for the lacquer to cure and adhere to the mirror. The mirror is then given a second coat of protective lacquer, which is then dried in an oven at 118°C. After 210 seconds, the lacquer is also cured and adheres to the mirror.
Finally, the mirror is acid-washed again to remove any excess metal residue. The workers then carefully inspect the mirror for defects. If there are any air bubbles, they are marked and then removed when the mirror is made into smaller pieces of glass.
This is how our copper-free silver mirror is made!
Smart Mirrors
As we all know, mirrors are particularly easy to break, and when they do, it’s hard to clean them up because they splatter all over the place. At the core of the smart mirror lies its chassis, the unsung hero responsible for housing the intricate web of wiring and electronic components. The fabrication of this central component involves the mastery of advanced machinery, including the Punch Press and Brake Press.
At BFY, we cut from 1.83*2.44/2.44*3.66/2.83*3.44 original plate without copper silver mirror according to the customized size. After cutting, it goes into the polishing machine for polishing. After polishing, the edge of the mirror becomes very smooth. After that, it enters the cleaning machine for cleaning, and while the machine is cleaning, our workers will trim the details of the mirror again.
To prevent the mirror from splashing around after breaking, BFY will put a layer of explosion-proof film on both sides of the mirror. After that, according to the customer’s customization, sanding, laser engraving of aperture, logo, and so on.
After that, according to the customization, we will install different LED strips for the smart mirror, to be more beautiful, our LED strips are hidden, our designers and engineers use aluminum to hide the LED strips, and install the whole LED light frame directly on the back of the mirror.
After that, we will install the hanging piece and the aluminum frame (according to the customization) in order, and install the corner protection package. According to the user’s customization, install the anti-mist film, electronic components, and so on.
Finally, the lights and buttons are tested. Thus our smart mirrors are ready. Usually, we use honeycomb boxes and pearl cotton when packing.
Quality Control
Quality control stands as the vigilant guardian at the threshold of smart mirror production, ensuring that every facet aligns with the highest standards. It is not a mere checkpoint; it is a meticulous examination that scrutinizes every detail. Imagine a team of experts meticulously inspecting the mirror surface, chassis, and integrated technologies, each element undergoing scrutiny to meet the stringent criteria set for excellence.
From the clarity of the mirror glass to the precision of the electronic components, quality control leaves no room for compromise. It is the gatekeeper that ensures the smart mirror not only meets but exceeds expectations. This meticulous process is not just about catching defects; it’s about elevating the mirror to a level where it becomes a symbol of uncompromising quality.
BFY supports all kinds of different smart mirrors customization, including size, shape, function, and so on. We provide sample service and a 2-year warranty service, so you can rest assured and worry-free.
Smart mirrors not only bring convenience to our lives but also add design and atmosphere to our rooms.
This article not only explains the process of making glass, but also explains the difference between different kinds of mirrors, and the process of making mirrors and smart mirrors, hope this science is useful to you, if you have hold questions, please contact us, and we are always ready to answer your questions.
