吉田ＳＫＴ List of Products and Services

"Bycoat(R)" is a coating system that achieves the ideal functions of "release properties" + "sliding properties" + "wear resistance" by combining inorganic and organic surface treatment technologies. It withstands harsh usage areas such as injection molds and product guides, providing reliable release and sliding properties. Additionally, due to its excellent dimensional accuracy, it is suitable for areas requiring micron-level dimensional precision. 【Features】 ■ Incredible durability ■ High hardness and scratch resistance ■ Excellent wear resistance ■ Outstanding non-stick and release properties ■ Safe for use in molds requiring micron-level dimensional precision *For more details, please refer to the PDF materials or feel free to contact us.

**Main Purposes of Mold Coating** - To extend the lifespan of molds by improving the hardness of the mold surface. - To enhance the quality of molded products by ensuring a smooth flow of resin. - To prevent resin adhesion by providing non-stick properties. **Main Types and Features of Mold Coatings** - **Chrome Plating** Chrome plating can improve the hardness of the mold surface. It also excels in wear resistance and corrosion resistance. - **DLC Coating** By forming a thin film called Diamond-Like Carbon (DLC) on the mold surface, it can enhance the hardness and non-stick properties of the mold surface. - **TiCN Coating** By forming a thin film called Titanium Carbonitride (TiCN) on the mold surface, it can improve the hardness, wear resistance, and corrosion resistance of the mold surface. - **Teflon Coating** By forming a Teflon resin with excellent non-stick properties on the mold surface, it can prevent resin adhesion. However, there may be cases where desired functions such as release properties and durability are not met with these surface treatments. If you are having trouble with mold coatings, please consider "Bicoat."

In mold forming, to stabilize product quality, it is important to improve release properties and prevent mold contamination. Measures such as PVD coating, DLC coating, and chrome plating are being implemented, but depending on the molding conditions, issues can arise where parts of the product stick, or eye residue becomes a cause of product defects. We would like to introduce coatings that have a proven track record of improving the release properties of molds. 【Selected Coatings (Partial)】 ■ Release properties, high hardness, dimensional stability (durable parts, molds) - Bi-Coat ■ Release properties, eye residue prevention - MRS Coating ■ Resin release at high temperatures - FSR Coating ■ Non-stick and slip properties - Teflon / Fluororesin Coating ■ Release properties, precision (precision parts, precision molds) - Nano Process *For more details, please refer to the PDF document or feel free to contact us.

"Die biting" refers to the phenomenon where resin sticks to or gets caught in the mold, causing scratches or defects in the molded products. This can occur when resin adheres to the mold's gates or flash surfaces, or when the mold patterns do not transfer to the surface of the molded products. When die biting occurs, it can lead to a decline in the appearance quality and dimensional accuracy of the molded products, potentially worsening product quality. Additionally, it may necessitate repairs or maintenance of the mold, which can adversely affect productivity. **Methods to Prevent Die Biting:** Surface Treatment: Properly treating the surface of the mold makes it less likely for resin to stick to it. Improvement of Gate Design: By considering the flowability of the resin and the balance of forces during withdrawal, a gate design can be implemented that prevents die biting. Optimization of Molding Conditions: Optimizing molding conditions can make it less likely for resin to stick to the mold. For example, it is important to appropriately set molding conditions such as molding temperature, injection speed, injection pressure, and holding pressure. Mold Maintenance: Proper maintenance can prevent the occurrence of die biting. Effective measures include cleaning the surface, correcting gates and flash surfaces, and using air blow.

There are various types of materials used for molds, but generally, the following are common: - Tool Steel: A type of steel that excels in wear resistance, heat resistance, and strength, used for the main parts of molds and cutting edges. - Cold Work Tool Steel: Known for its high hardness and dimensional stability, used for small parts of molds and complex-shaped components. - Hot Work Tool Steel: Maintains strength and dimensional stability even at high temperatures, used for large mold components and parts used under high temperatures. - Aluminum Alloy: A lightweight and highly workable material used for molds in low-pressure casting and high-pressure casting. - Copper Alloy: Possesses high electrical and thermal conductivity, used for molds in plastic injection molding and die casting. - Ceramics: A material that excels in heat resistance and wear resistance, used for molds that operate at high temperatures and for precision molding. As such, various materials are used for molds depending on their applications. Choosing the appropriate material is essential, but selecting the right surface treatment is also important for the mold's lifespan and product quality. Do you have any concerns regarding surface treatment for molds? <Molding Equipment> - Mold damage - Mold dimensional accuracy - Coating peeling

Mold release residue refers to foreign substances that adhere to the surface of molded products when forming thermoplastic materials such as resins and rubber. To prevent this residue, it is necessary to avoid material retention in the mold. When appropriate material selection and molding conditions cannot resolve the issue, adopting a surface treatment with excellent release properties is effective. Here are examples of improvements in mold release residue through surface treatment. ■ Concern We received an inquiry from a customer who was prototyping a new elastomer extrusion product. They wanted to resolve issues related to product stability due to adhesion in the extrusion mold. ■ Background for Coating Adoption Initially, the adhesion was so severe that it was impossible to form the product, but after adopting our surface treatment, we were able to prevent adhesion to a level that allowed for production. However, during continued mass production, it became apparent that defects due to residue adhesion occurred after about a month of use. ■ Selected Surface Treatment 'MRS Coating MRS-102' *For details on 'MRS-102', please download the PDF or contact us. The effects of the surface treatment are listed below.

We would like to introduce a case study of surface treatment for molds used in blow molding PET resin. ■Challenges In the molds used for blow molding PET bottles, a coating was applied to improve release properties, making it easier for the resin to detach after molding. However, with the previous coatings, there were instances where the resin, softened by heat, would slightly adhere and remain, potentially leading to cloudiness in the PET bottles, necessitating frequent maintenance of the molds. ■Effects of the Adopted Coating We adopted our "Super Bi-Coat NYK-01-F05." This coating maintains performance characteristics such as film thickness precision and hardness comparable to previous bi-coats while improving release and slip properties during high-temperature molding. It reduces resin residue on the molds and enhances the transparency of the PET bottles. 【Key Points of the Case Study】 ■Purpose of Surface Treatment Reduction of work loss, stabilization of quality and operation ■Required Functions Non-stick and release properties, sliding and slip properties, wear resistance ■Adopted Treatment 'Super Bi-Coat NYK-01-F05' *For more details, please refer to the PDF document or feel free to contact us.

■Concern When molding rubber of different materials in layers, the products molded in the mold enter the vulcanization process while still in the shape of the mold. The products were made of materials that easily adhered to the mold, resulting in a phenomenon where they stuck to the mold and could not be removed after vulcanization. ■Background During demolding, strong forces are applied, so using standard fluororesin coatings posed a risk of peeling due to insufficient film strength. We recommended a Bi-Coat that excels in release properties and wear resistance, but the mold in question was made of soft aluminum and required surface treatment compatible with sulfur vulcanization, necessitating the selection of a Bi-Coat treatment that could adapt to both conditions. ■Coating Adopted Super Bi-Coat NYY-11-F05 ■Adoption Process and Effects We tested a Bi-Coat suitable for aluminum substrates and usable for sulfur vulcanization. Initially, demolding was good, but rubber adhesion began to occur within a short period. Therefore, we proposed and tested the "Super Bi-Coat NYY-11-F05," which excelled in release properties, achieving both initial demolding and sustained release properties. This led to its adoption. *Product data PDF is available for download.*

We would like to introduce a case study that resolved film adhesion issues that could not be solved with fluororesin coating on fusion molds. ■Consultation Details In the fusion process where a film is used to cover a container, the fusion mold is heated to over 100°C, causing the surface of the film to melt. Initially, fluororesin coating was applied to the mold to prevent film adhesion. ■Background of Selection Due to the material of the film and the melting temperature, film adhesion to the fusion mold was causing product defects. The mold has small holes for vacuuming the film, and there were limitations on options due to conditions such as not blocking these holes. ■Coating Adopted 'TP Coating' ■Adoption Background and Effects To meet the customer's usage conditions, we proposed a coating that has better release properties than the current coating and does not block the mold's holes, reducing the contact area. The customer adopted the "TP Coating," which has excellent release properties and does not affect vacuuming. *For more details, please refer to the materials or contact us directly.

■Concern Due to the different moldability of biodegradable plastics compared to regular plastics, there were issues with mold release in the prototypes, leading to molding troubles. ■Background We received this consultation because there is no track record of surface treatment with the materials being molded, and we do not know the appropriate surface treatment. ■Coating Adopted Bicoat Exceed NYK-2000E ■Adoption Process and Effects At Yoshida SKT, we prepared a collection of samples suitable for mold release from molding molds, and confirmed the release properties with actual plastics. We processed the well-performing NYK-2000E into the prototype mold, and it has been used without issues for several months. *Detailed surface treatment materials can be downloaded as a PDF.

In a production line, troubles such as the following can occur at any time: ■ Line stoppage ■ Delay in takt time ■ Increase in defects ■ etc... When such problems arise, quick responses and identifying the causes are important, but learning preventive measures in advance can help avert emergencies. By imparting "release properties and slip properties" through surface treatment, we are currently offering free "trial sets" that have actually improved production processes, as well as a "case study collection on process improvement." For more details on the cases, please download the "case study collection on process improvement" and check it out. You can apply for a free trial set of surface treatment samples through the "related links." We encourage you to take this opportunity to apply.

In the production line, troubles such as the following can occur at any time: ■ Line stoppage ■ Delay in takt time ■ Increase in defects etc… When such problems arise, prompt response and investigation of the causes are important, but by learning preventive measures in advance, we can avoid emergencies. By imparting "release properties and slip properties" through surface treatment, we are currently offering free "trial sets" of surface treatments that have actually improved production processes, as well as a "case study collection for process improvement." For more details on the cases, please download and check the "case study collection for process improvement." You can apply for a free trial set of surface treatment samples from the "related links." We encourage you to take this opportunity to apply.

Terms related to molds include the following: [Mold-Related Terms] - Shot: The unit amount of molten resin injected from the injection port in injection molding. - Gate: The part within the mold where molten resin flows in during injection molding. - Ejector Pin: A pin that moves with the operation of the mold to remove the molded product from the mold. - Laminated Plate: An element that constitutes the mold, consisting of multiple stacked plates. - Drilling Process: One of the manufacturing processes for molds, involving creating holes in metal plates, etc. - Heat Treatment: A process of heating and rapidly cooling metal materials to extend the durability and lifespan of the mold. - Wear: Refers to the wear that occurs due to the use of the mold, which affects the mold's lifespan. - Casting Mold: A mold used in casting. - Design Drawing: A drawing created by the designer in the mold design process. - Assembly: The process of assembling the various components of the mold. - Mold Surface Treatment: A technique that can improve wear resistance or release properties on the surface of the mold. These are basic terms that people involved in mold manufacturing, operation, and maintenance should be familiar with. Below, we will introduce surface treatments.

The materials used for molds are durable materials such as metals and plastics. The selection of materials for molds is determined by factors such as the shape of the product, the number of products to be mass-produced, the production process, and the types of materials used. Generally, for metals, the following types are available: 【Types of Mold Materials】 - Steel: It has high wear resistance, corrosion resistance, heat resistance, and strength. Examples include P20, S136, and NAK80. - Aluminum Alloy: Lightweight and highly heat-resistant, it may be used in processes such as injection molding. - Copper Alloy: It has high conductivity and excellent thermal conductivity. An example is beryllium copper. - Magnesium Alloy: Lightweight, strong, and has excellent thermal conductivity. It may be used in automotive parts. - Tungsten Alloy: It has high hardness and is suitable for use at high temperatures. It may be used in injection molding molds. The materials used for molds directly affect the quality of the products and production efficiency, so it is important to select appropriate materials and surface treatments according to the properties of the materials. Do you have any concerns regarding surface treatment for molds?

An elastomer is a type of synthetic resin that possesses elasticity and can change shape, being a polymer compound that has both rubber and plastic properties. This time, we received a consultation regarding the inability to produce stable products due to the occurrence of eye mucus in the mold during the extrusion molding of elastomers. ■ Background for Coating Adoption - Without surface treatment, the elastomer adhered to the mold to the extent that almost no products could be manufactured. - By adopting our Bi-Coat, we were able to prevent adhesion to a level that allowed for production. - It was found that after about a month of mass production, defects due to the adhesion of eye mucus occurred. ■ Effects of Surface Treatment Adoption - After adopting our 'MRS-102' and starting tests, eye mucus did occur, but it did not adhere to the mold and could be easily removed, which helped suppress the occurrence of defects, allowing for continuous use for six months. *For details on the adopted 'MRS-102', please refer to the materials or contact us.

Releaseability of a mold refers to the property that allows a product to be smoothly released from the mold. Poor releaseability can lead to issues such as prolonged release time or damage to the product. One effective method to improve releaseability is coating. Coating enhances non-stick properties and improves releaseability by forming a film on the surface of the mold. Depending on the type of coating, the characteristics such as the types of materials with excellent releaseability, durability, and wear resistance vary. Additionally, the appropriate coating differs based on the material and shape of the mold, as well as the type of resin being molded. "Bycoat" is a system that achieves the ideal function of "release + wear resistance" by combining "inorganic surface treatment technology" and "organic surface treatment technology." It withstands harsh usage areas such as injection molds, providing reliable lubrication and releaseability. Furthermore, due to its excellent dimensional accuracy, it is suitable for areas requiring micron-level precision. By processing with Bycoat, releaseability can be improved, reducing product defects and enhancing productivity. *Product materials and case studies are available for PDF download.*

Introduction of Bycoat to meet needs such as: - Residual products on molds - Filling defects in thin-walled molding - Release agent transferring to molded products - Decorative sheets sticking to molds during transfer 'Bycoat' is a system that achieves the ideal functions of "release + wear resistance" by combining "surface treatment technology for inorganic materials" and "surface treatment technology for organic materials." It withstands harsh usage areas such as injection molds, providing reliable lubrication and release properties. Additionally, it is suitable for areas requiring micron-level dimensional accuracy due to its excellent processing dimensional precision. By processing with Bycoat, you can improve release properties, reduce product defects, and enhance productivity. *Product materials and case studies are available for PDF download.

The high durability coating for molds, "BicoatⓇ NYK-01," is a high-performance surface treatment that reduces resin adhesion and wear in injection molding, thereby improving productivity. With a special coating designed for use in high-temperature environments, it achieves approximately twice the lifespan compared to conventional surface treatments. This contributes to reduced replacement frequency and lower running costs. It has a proven track record with automotive motor parts manufacturers and is a trusted coating technology that leads to regular requests. 【Features】 ■ Incredible durability ■ High hardness, resistant to scratches ■ Excellent wear resistance ■ Superior non-stick and release properties ■ Safe for molds requiring micron-level precision It demonstrates wear resistance under high-temperature and high-pressure conditions, preventing adhesion from molten resin. Test results have confirmed approximately twice the lifespan compared to conventional surface treatments. It enables smooth mold release during forming and is ideal for customers aiming to improve productivity. If your company is considering reducing replacement frequency and material costs, please feel free to consult with us. *For more details, please refer to the PDF materials or contact us at your convenience.

"Bycoat® NYK-01" is a surface treatment technology that significantly improves the durability of molds in the injection molding process. It has particularly strong resistance to the adhesion of molten resin and wear, contributing to increased productivity and cost reduction. 【Features】 - The high-hardness coating, which excels in wear resistance, doubles the durability compared to conventional products. - It has excellent non-stick properties, suppressing the adhesion of molten resin. - It maintains effectiveness even under high temperature and high pressure conditions. 【Applications】 - Injection molding molds for automotive motor parts - Ideal for molds used in high-temperature resin molding 【Track Record】 - Adopted by major automotive parts manufacturers - Regular repeat orders after adoption for new molds 【Features】 - Doubles durability compared to conventional products. - Significantly reduces work loss and mold replacement frequency. - Exhibits excellent performance even under high temperature and high pressure conditions. Recommended for those facing challenges with resin adhesion prevention or wear-resistant coatings. Please feel free to contact us!

■Issue In injection molding components, the durability of the mold surface treatment is poor, requiring frequent replacements and hindering productivity. ■Solution Gradually adjust a surface treatment that is resistant to wear from molten resin and has lasting effectiveness, adopting the optimal coating. ■Customer's Challenge A manufacturer of automotive parts faced the following issues in the injection molding process of motor components: ■Details of the Issue Even with surface treatment, epoxy resin adhered, necessitating replacement after about 2,000 shots. Frequent mold changes led to decreased productivity and increased costs. ■Conditions for Surface Treatment Selection Contact with molten epoxy resin under high temperature (150°C) and high pressure. Improving wear resistance is the top priority. ■Solution Method To improve the durability of the surface treatment, tests were conducted with multiple coating specifications to consider the optimal treatment. The following surface treatments were tested: - Bi-Coat NYK-11-S Durability comparable to conventional products - Bi-Coat TYS-03K Lifespan of a few hundred shots - Bi-Coat NYK-01 (Adopted) Durability improved to twice that of conventional products Recommended for those facing issues with resin adhesion prevention and wear-resistant coatings. Please feel free to contact us!

Here is a case study of a certain automotive parts manufacturer. In the process of injection molding epoxy resin under high temperature and high pressure of 150°C, resin adhesion began after about 2,000 shots, necessitating frequent mold changes. The introduction of "Bicoat NYK-01" improved mold life by approximately twice, achieving a significant enhancement in productivity. 【Issues that can be addressed】 ■ Short lifespan of surface treatment for injection molding molds ■ Decreased productivity due to frequent mold changes ■ Resin adhesion issues in high temperature and high pressure environments 【Expected effects】 ■ Achieving approximately twice the mold (surface treatment) lifespan compared to conventional methods ■ Significant reduction in mold change operations leading to increased productivity ■ Reduction in replacement and material costs ■ Stable production due to excellent non-stick and release properties For more details on the case, please refer to the page "Doubling the Durability of Mold Surface Treatment in Automotive Motor Parts Manufacturing." *Product data PDF is available for download.