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Short-Time Molding and Processing System for Thermoplastic Composites, Patent No. 5826243
Development of General-Purpose System for Short-Time Molding and Processing of Thermoplastic Composites
Thermosetting resin composite materials, such as epoxy resin, which have low productivity and are not suitable for mass production, are expensive and have a limited track record of use. However, in order to dramatically improve their productivity, support mass production, and reduce costs, we have jointly developed with companies and universities a process for molding thermoplastic composite materials in a short period of time.This will help to open up new markets in industrial fields that have had little experience with the use of such materials.
Main Achievements
- Metal press manufacturers
- Plastic molding manufacturers
- Material manufacturers
- Prepreg manufacturers
- Public institutions such as industrial technology centers
System Features
Existing press machines for thermosetting resin molding and metal forging press machines are easily modified and converted, enabling short-time molding of thermoplastic composites with only the introduction of a dedicated die and temperature controller.
- Supports both thermoplastic and thermosetting prepregs
- Supports cold press molding in a short time by using a near-infrared lamp heater
- Enables hot press molding while impregnating resin by employing a dedicated mold
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Equipped with 16 independent channels for stable mold temperature control
・Enables automatic regulation of heater and cooling water flow during heating and cooling -
Easy to set conditions using software developed exclusively for composite molding
・Large touch panel for easy viewing and improved operability
・Connecting to a PC enables management of molding conditions and data editing
Overview of Composite Material Molding
- The molding cycle is extremely fast because the material (plate) is heated and pressed in a die at the appropriate temperature, which is ideal for large or deep products.
- Using rolled material makes it easy to cut and eliminates the need for trimming after molding.
- It is ideal for semi-prepreg molding as the material can be impregnated during molding (pressing.)
Design and Manufacture of Carbon Composite Products
Solving your carbon composite product manufacturing problems
Our technical center specializing in carbon composite products (fiber-reinforced composites) was opened in 2017.By combining carbon fiber fabrics (cloth materials), glass fiber fabrics, and unidirectional UD materials and stampable sheets, we aim to help with your product manufacturing concerns by using our technology to design and manufacture composite material products tailored to your application needs.
Main Achievements
- Major electronics companies
- Creating prototypes for items prior to implementation testing
Equipment Overview
・Go Molding System | Short-time general-purpose molding system with high-speed heating & cooling control | Made by Go Factory
・ZENFormer 100t | 6-Axis direct drive digital servo press | Made by Hoden Seimitsu Kako Kenkyusho Co., Ltd.
・MDV200TY-GMS | Heating & cooling type CFRTP composite molding machine | Made by Niigata Machine Techno Corporation
Materials Handled
Thermoplastic prepreg
Carbon fiber fabric (CF), glass fiber fabric (GF), aramid fiber fabric (AF), unidirectional reinforcing agent (UD material) (CF), stampable sheet (CF/GF)
Resin (Material)
PP, PA6, PA12, PC, PPS, PES, PEI, PEEK, PI, etc.
Thermosetting prepreg
Carbon fiber fabric (CF), glass fiber fabric (GF), aramid fiber fabric (AF), unidirectional reinforcing agent (UD material) (CF), stampable sheet (CF/GF)
Resin (Material)
Epoxy resin, phenol resin, urethane resin, unsaturated polyester, etc.
Semi-prepreg
All sorts
From Design to Processing of Thermosetting Resin Molded Products
We Can Accept Small-Lot Orders - Leave Your Design Prototypes, etc. to Us
We can deal with a wide variety of materials through processing backed by our experience and technology.This includes thermosetting resins used in products where insulation, flame retardance, and heat resistance are important.Our designs are tailored to various products, and we process them using materials suited to the application.We can handle small-lot orders too, so just leave things like design prototypes to us.
Main Achievements
- Major electronics company - Making prototypes for items prior to mounting tests
- Major electronics company - Making connectors for stage lighting
Examples of Thermosetting Resin Molded Products
Mainly for products requiring insulation, flame retardancy, heat resistance, etc., such as heavy electrical machinery and connectors
Materials handled:
Phenol resin, epoxy resin, unsaturated polyester resin (SMC, BMC), urea resin, melamine resin, diallyl resin, etc.
Molding Methods
Injection molding, compression molding, transfer molding, seal molding, etc.
From Design to Processing of Thermoplastic Resin Molded Products
Supporting design and processing using super engineering plastics
We provide a one-stop service for mass production, including 3D design, mold making, and machining.Feel free to contact us about the design and processing of products using super engineering plastics, which is our particular area of expertise.
Main Achievements
- Dental clinic | Design and fabrication of orthodontic mouthpieces
- Major camera manufacturer | Lens hood, Digital camera mock
- Major medical device manufacturer | Parts for medical equipment
Examples of Thermoplastic Resin Molded Products
Everyday plastic products such as home appliances, medical products, household goods, etc., from general-purpose plastics to super engineering plastics
Materials Handled
PP、PE、PB、PS、EVA、TPU、TPO、PMMA、POM、ABS、PC、PA、TPX、PPO、PPE、PET、PES、PPS、PSU、PEI、PEEK、PFSF、PI
Molding Methods
Injection molding, extrusion molding, two-color molding, blow molding, vacuum molding