This workflow describes a two-stage route for zamak, pewter, zinc alloys, and tin alloys: a LUXI Brown first stage followed by a LUXI Pink finish. It does not apply to polymers, cold enamels, or every soft metal automatically.

LUXI Brown must fully complete the first stage before LUXI Pink is used. The finishing compound must not correct incomplete preparation, deep scratches, cracks, open cavities, or geometry errors.

Entry condition

Before polishing, complete:

  • item geometry;
  • required repair;
  • removal of major protruding defects;
  • even abrasive preparation.

For some tasks, P400 may be a minimum starting point, but preparation to P600 or finer is preferred. Zinc and tin alloys are often prepared to P600–P800 or by a correctly completed tumbling process. Exact preparation depends on the alloy, item shape, contact area, and required result.

The surface must not retain isolated marks from a coarser abrasive, deep scratches, waviness, or unfinished shape.

First stage — LUXI Brown

Use a separate clean white stitched cotton wheel or white stitched muslin wheel.

For a wheel approximately 150 mm in diameter, the confirmed starting range for the metal branch of LUXI Brown is 2800–3000 rpm. This range does not belong to the polymer branch and must not be transferred automatically to another diameter.

For another diameter, consider linear surface speed, contact area and stability, rpm drop under load, temperature, and the behaviour of the particular alloy.

Apply LUXI Brown minimally to a clean wheel. Work in short passes, keep the item moving, and control pressure and temperature. Do not compensate for incomplete preparation with excess compound, increased pressure, or prolonged continuous contact.

The first stage is complete when, after LUXI Brown and removed metal have been eliminated:

  • no visible marks from the last abrasive remain;
  • the surface is even with a slight lustre;
  • edges, relief, and intended geometry are preserved;
  • no smearing, overheating, or waviness is present.

If preparation marks remain, check abrasive preparation, wheel cleanliness and activity, the amount of LUXI Brown, rpm, pressure, and contact duration. Do not move to LUXI Pink until LUXI Brown is fully complete.

Cleaning between stages

Remove LUXI Brown, removed metal, and wheel contamination completely. Allow the item to cool and inspect the surface under directed light.

Use a separate clean tool for LUXI Pink. LUXI Brown residue must not be transferred to the finishing wheel.

Finish — LUXI Pink

Use LUXI Pink on a separate clean white unstitched Calico wheel. Muslin, flannel, felt, and stitched cotton wheels are not the primary LUXI Pink tools.

For a wheel approximately 150 mm in diameter, use 2500–3000 rpm as the working starting range. For another diameter, select the conditions according to linear surface speed, contact area, wheel stability, temperature, and the behaviour of the particular alloy.

Apply LUXI Pink minimally. Work in short passes, keep the item moving, and control temperature and pressure especially carefully on soft alloys.

LUXI Pink must bring the already formed LUXI Brown surface to an even mirror reflection. It must not remove visible marks from the last abrasive or reform geometry.

Completion criterion

The process is complete when, after all compound has been removed and the item is dry and cool:

  • the surface shows an even mirror reflection;
  • no dull zones or previous-stage marks remain;
  • no compound or removed metal remains in relief, recesses, or joints;
  • edges, relief, and geometry are preserved;
  • the result remains stable after cleaning and cooling.

Stop conditions

Stop if the process produces:

  • noticeable overheating;
  • smearing of the soft alloy;
  • waviness or loss of flatness;
  • edge loss or relief smoothing;
  • increasing haze;
  • opened or growing pores, cracks, or cavities;
  • an unstable result after cleaning and cooling.

These conditions require a return to preparation, repair, or production-suitability assessment rather than an automatic increase in compound, pressure, or contact duration.

Cleaning and coatings

Select the cleaning method for the whole item: alloy, construction, inserts, joints, coating, and next operation. LUXI iClean, ultrasonic cleaning, heated solution, solvent, and steam are not prescribed automatically.

Do not mechanically polish a thin decorative, protective, electroplated, or PVD coating that must be preserved. Identify an unknown coating first.