In order to produce high cycle molds, we design and produce appropriate cooling circuits based on data accumulated over the years and our unique cooling design. Furthermore, by switching to a hot runner and eliminating a runner, it is possible to eliminate unnecessary runner cooling time for the molded component.
In order to achieve a high cycle, we take the customer’s perspective and propose precision molds for thin walled molded components and shortening of the mold cycle.
We manufacture precision molds which can sufficiently withstand long life molding, by our mold design focusing on rigidity of the mold. There are many points to consider in achieving the manufacture of a highly durable long life mold.
We will reduce the total cost of precision mold manufacture by reducing frequency of maintenance and repair.
Fuji Seiki has acquired a 3D printer to allow us to make the image of the product under development more real when showing the design of the development to supervisors and other people involved in the product development.
In addition, it is possible to reduce test piece cost as it is no longer necessary to manufacture test pieces.
Using flow analysis, it is possible to test for non-conforming mold product in advance. Advance testing of runner and resin filling balance in multi-cavity molds is possible.
Fuji Seiki’s ultra-precise mold manufacture integrates design and manufacture. We propose designs which guarantee parts precision and manufacturing implements a Design Review to seek further improvements in precision.
Furthermore, for die set mold precision, we implement the same degree of control of dimension precisions as other mold parts.
We design molds using structural analysis of mold strength required for molding of molded components with the required precision, and after manufacture the precision molds are inspected by checking against measurement data.
Ultra-precision is essential for mold parts of parts for molding precision molded components and we control measurements to the sub-micron level.
Our inspection system is a twofold inspection system as first of all the processing technician implements their own measurement in the processing machinery, and this is followed by measurements by specialist inspection staff using 3D measuring apparatus, circularity measuring equipment and other high precision inspection apparatus.
About technical developments we are actively pursuing
It is crucial to guarantee precision of each molded part in the manufacture of ultra-precise molds.
We use a diverse range of measuring equipment and only parts which have passed the final measurement by measurement engineers are incorporated in the mold.
Furthermore, after completion of the ultra-precise molds, the mold performance and molded components of all molds are checked on our in-house trial injection molding machine.
We also conduct joint development of products (molded components), drafting product (molded component) drawings and manufacturing trial molds utilizing CAD/CAE (various analysis) on behalf of our customers.
We have 9 trial manufacture molding machines from 75T to 450T, so we can depending on the requirements of our customers, we can offer support for small lot manufacture of molded components.
We can also offer support of specialist staff for start up of molds when molds are delivered.
We can also hold study meetings at our company, and in for maintenance which invariably becomes necessary during mass production, molds can be sent back to our company for maintenance or we can also visit customers to give instruction on maintenance.
Once manufacture is started up, the frequency of problems is extremely low, and the molds enable a continuous stable production which is unmatched elsewhere, and furthermore, although it is a multi-cavity, there is no deviation between cavities and we have succeeded in simplifying quality control on the production line.
Inoue: We have accumulated results and knowledge built over time in the manufacture of a diverse range of molds for a variety of industries, and our company is imbued with a spirit of seeking new challenges. We look forward to hearing the inquiry “you can make this kind of precision mold, can you?”
Tochika: We are confident in the wealth of experience we have accumulated in resin materials and product shapes. Furthermore, recently various kinds of analysis using CAE can be done in advance and we can utilize this to give advice on product shape. We aim to be a company our customers rely upon!