The raw material is melted by electrically heating it to 150-280 degrees Centigrade, and then it is injected into the metal mold.
Once the material has cooled and set into shape, the metal mold automatically opens, and the product is lifted out by a robot and placed on a conveyor belt for finishing touches.
General Injection Molding Representation of the Forming Process
The forming method will depend on the function expected of the end product. We use the following forming techniques to produce products that cater to the requirements of our customers.
Two-color forming is a technique used for molding the same material of two different colors, thereby producing products with striking designs. Unlike painting and hot stamping, two-color forming can create products with durable decoration and a sense of high quality. Different-material forming is a technique in which two types of material are adhered together during the forming process so as to produce an end product in which two different sets of properties co-exist. Because the need for latter processes such as adhesion work is eliminated, costs are brought down. These techniques also expand the applications of products.
Simultaneous Forming Representation of Forming Process
Core Back Representation of Forming Process
Rotary Representation of Forming Process
Our gas-injection technique involves injecting nitrogen gas into the thicker parts, thereby creating lighter weight and better structural strength while also preventing sagging and warping.
Gas-Injection Representation of Forming Process
Press forming is a technique that involves opening a metal mold and running resin into the widened-out fluid passage without excessive pressure. Because the material can be molded at low pressure, it is possible to create finished products with minimal warping. In addition, the spreading caused by pressing at the same time, makes the flow distance much greater compared to general injection forming. For this reason, it is possible to form products with a larger projected area using molding machines with low clamping power.
General Press Forming Representation of Forming Process
Two-Color Forming Representation of Forming Process
Aside from the forming techniques, there are many products that can be shipped as sub-assemblies or in their final form. Aside from injection formed products, we have an extensive lineup of assembled products such as metal chassis, mechanical components, soundproofing materials and rubber products.
Simple caricatures and conception pictures etc. are turned into 3D-CAD diagrams. At this stage, we carry out various examinations, including a general evaluation of the metal mold construction, product weight calculations, and assembly interference checks.
The data yielded from these examinations can also be used in subsequent flow analysis.
We then use the 3D plan developed in the first step to develop a 2D design, which will be used for preparing the metal mold.
If preliminary trials highlight potential difficulties such as complex shapes or gate location issues, we will run a flow analysis.
At this step, we use the 3D data obtained in the first step to locate gates and select the resin, and work out the optimum conditions for pressure and time during molding.
Based on the resulting data, it will be possible to significantly reduce post-molding corrections.