Case examples of mold manufacture | Fuji Seiki

Resin material	PP
Number of cavities	16~48 cavities

-Problem experienced by customer: The product unit price was extremely low, and without lowering the product cost, they would be unable to compete on the global market. They required a proposal for lowering product unit price. -Method of resolving problem We succeeded in utilizing the existing molding equipment, increasing product volume per unit of time by increasing number of cavities to decrease product cost. -What were the customer’s comments upon completion? Although it is a multi-cavity mold, stable production with no variations has been realized. In the future we would like to further use Fuji Seiki molds for major product molds.

Resin material	elastomer
Number of cavities	16~128 cavities

-Problem experienced by customer They asked us whether the number of cavities could be doubled to improve production efficiency and realize a lower product unit price. -Method of resolving problem We focused on controlling variation of product quality and succeeded in doubling the number of cavities from 64 to 128. -Creative measures employed in manufacture We utilized our analysis technology to analyze runner balance and control variations in accuracy of dimensions of each product. -What were the customer’s comments upon completion? The number of cavities was doubled without lowering mold cycle, so it was a great contribution to production. We would like to consider an update of existing molds.

Resin material	PP
Number of cavities	2 cavities

As it is PP, the shrinkage ratio is high, and stable molding is difficult to achieve with this material.

Therefore, we designed a system with a fast cycle and stable quality. We were creative with the cooling method etc. This kind of knowhow is our company’s original knowhow, so we cannot write in detail here. If you have similar difficulties, please do not hesitate to contact us.

Resin material	PS
Number of cavities	6 cavities~32 cavities(stack mold)

-Problem experienced by customer These days foreign products are flooding the Petri dish market, price competition is escalating and we were asked whether there was a way to reduce product unit price. -Method of resolving problem Our proposed methods to resolve the problem included 1) increasing cavities,　2)improving production efficiency by increasing mold cycle, and 3)taking measures to reduce material costs. Also, by utilizing a stack mold, production volume could be doubled using the existing equipment. -Creative measures employed in manufacture While considering product strength, we succeeded in lightening the product and reducing material costs by approximately 13%. -What were the customer’s comments upon completion? As a reduction in product cost was achieved, we were able to compete in price with overseas products.

Resin material	PP-PE
Number of cavities

-Problem experienced by customer
The product unit price is extremely low and it is difficult to make a profit without a high volume of production, so the customer requested product cost cutting proposals.
Also, the product start-up time is extremely short and they requested cooperation in a quick start-up.

-Method of resolving problem
We took measures to increase cavities and ensure a high cycle.

-Creative measures employed in manufacture
We work on mold creation, participating from the product development stage through to product design review, making proposals considering filling efficiency and weld measures.

-What were the customer’s comments upon completion?
Maintenance frequency was cut for the existing mold, contributing to a significant increase in productivity. We would like to have Fuji Seiki’s cooperation in our future product development.

Resin material	PP
Number of cavities	6 cavities~12cavities

-Problem experienced by customer This product must be mass produced and the issue is how far the product cost can be lowered. -Method of resolving problem We achieved even greater high cycle molding and reduced material costs, thereby lowering product unit price. -Creative measures employed in manufacture We achieved the maximum possible thinness while maintaining product strength, reducing materials cost. While high speed injection is required, we increased rigidity of mold and succeeded in creating a mold which prevented thickness deviations. Also, we created a lighter mold in order to improve mold life. -What were the customer’s comments upon completion? FUJISEIKI’s molds are greatly contributing to stable production. We would like to use FUJISEIKI molds for long seller products in the future.

Resin material	PC(GF30%)
Number of cavities	1 cavity or 2 cavities

-Problem experienced by customer
The customer requested cooperation with differences in level in mold layout of appearance part, roundness precision, mold cycle, a shorter time from arrangement to production start-up, and reduction of product unit price.

-Method of resolving problem
We improved mold rigidity and precision and increased cycle and reduced costs by proposals on product shape.

-Creative measures employed in manufacture
We utilized improvements in jobbing precision by 4-axis processing machinery and our knowhow of processing fixtures and controlled parts precision using dedicated measuring equipment and controlling inspection data.

-What were the customer’s comments upon completion?
The difference in level of layout of the product was greatly reduced, and mold parts values strictly controlled, making it easier to make corrections using comparative assessment with product measurement and improving product quality.

Resin material	PMMA
Number of cavities	1~2 cavity

Control of vibration and temperature are the keys to precision micro-machining of prism pattern, and this processing is done in a special processing environment. (room temp: 23℃±0.1℃) Vibration control and control of precision cutting tools is extremely difficult, and processing is done by dedicated veteran engineers. Processing size(500X480)