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Once the graphics are finalized, manufacturers move to the creation of the tin boxes themselves. The process involves cutting and shaping sheets of steel, which are coated with a layer of tin to prevent rusting and ensure durability. The pieces are then pressed into shape and assembled—usually featuring a hinged lid and a sturdy handle, reminiscent of the lunch boxes popularized in the mid-20th century.
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Hot-dip galvanizing entails immersing the prepared metal in molten zinc, resulting in a thick, durable coating that provides excellent corrosion resistance. On the other hand, electro-galvanizing uses an electric current to bond the zinc to the surface, producing a thinner but more uniform layer. Once the galvanization is complete, the windows undergo further processes such as painting or powder-coating to enhance their aesthetics while providing an extra layer of protection against weather elements.
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