加藤製作所 List of Products and Services

Deep drawing processing of aluminum and stainless steel materials widely used in the aircraft and medical device industries. This type of difficult-to-machine material requires specific techniques and know-how for drawing press processing. Additionally, depending on the method, cost reductions such as mold expenses are also possible. Kato Manufacturing has obtained the certification standard AS/EN/JISQ9100:2009 (Manufacturing of Aerospace Sheet Metal Processing Parts). With "drawing press processing technology" and "opposing hydraulic press" as its unique core technologies, the company has been proposing cost reduction from the design stage to many companies for many years. Currently, the company is offering two free books: 'Examples of VA Cost Reduction in Drawing Press Processing' and 'Press Technology Handbook for Designers,' which compile years of achievements and experience. These are essential technical materials for VA cost reduction design. Limited to the first 50 applicants, so please act quickly! ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ ★ Free distribution of case studies & technical handbook (limited to 50 people) ★ If you are interested, please request through the "inquiry form." ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━

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Kato Manufacturing, equipped with a press machine dedicated to deep drawing, has mastered the art of deep drawing. By accommodating complex shapes and difficult-to-process materials, we showcase our high-level technology, earning us the nickname "Kato of Drawing" from many customers. Our site is not just a technical introduction; it also provides information that leads to quality improvement, labor reduction, and cost reduction.

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This is an information site for solving issues related to press processing conditions for difficult-to-machine materials such as Inconel, Hastelloy, titanium, nickel, aluminum, and stainless steel. Through case studies from our "Difficult-to-Machine Material Press Test Center," it serves as a resource to help customers resolve their challenges.

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This is a technical information site that provides information that designers should know, which can lead to cost reduction, including points to consider when designing machine parts from the perspective of press processing, common troubles that can occur in the production site, and how to address them from the design stage.

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A must-have guidebook for press processing engineers is available for free! It is packed with information that leads to cost reduction and improved design capabilities in press processing. This book includes knowledge on VA/VE, processing steps, case studies of VA/VE proposals during the design phase, points to consider when designing machine parts, common troubles that occur in production sites, and methods to prevent issues during the design phase. This single book will dramatically change the press processing field. ◆◇Free gift for the first 100 applicants! Please apply early◇◆ [For more details, please download the catalog or feel free to contact us] *The catalog download will be a digest version.

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This is an introduction to deep-drawing products in a round shape. The stepped areas can also be drawn without scratches. Among drawing press processing, we can perform the challenging taper processing (a gradient or slope that tapers to a point) in a single step (reducing mold costs through process reduction). We offer three types: opposing hydraulic forming, hydraulic forming, and mechanical forming, allowing us to respond with processing methods suited to product characteristics. 【Features】 ○ Capable of forming complex shapes ○ Forming without surface scratches is possible ○ Local thickness reduction can be minimized ○ Dimensional accuracy can be improved ○ Production process steps can be shortened For more details, please contact us or download the catalog.

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Corner-drawn products can be mass-produced using progressive die processing. We can also accommodate irregular corner-drawn products that require high precision in perpendicularity and flatness. We can accept small to medium-sized items through progressive processing as well. We can also handle ultra-deep drawn square products that require no surface wrinkles or shock lines (drawing marks) and demand high tensile rigidity. 【Features】 - Capable of forming complex shapes - Forming without surface scratches is possible - Local thickness reduction can be minimized - Improvement in dimensional accuracy can be achieved - Production process steps can be shortened For more details, please contact us or download the catalog.

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The irregular deep drawing that was said to be impossible with press processing can be realized with the technology of Kato Manufacturing Co., Ltd. Even difficult-to-draw soft materials like aluminum can be evenly deep drawn. Both round and square (complex shapes) can be formed simultaneously. Additionally, deep drawing enhances design aesthetics. 【Features】 - Capable of forming complex shapes - Forming without surface scratches is possible - Local reduction of plate thickness can be minimized - Dimensional accuracy can be improved - Production process steps can be shortened For more details, please contact us or download the catalog.

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We have the know-how to perform high-quality deep drawing processes, including mouth-drawing processing, wobble processing, thick-walled pipe shape drawing, and ultra-large round rings, which are highly challenging. We can also perform mouth-drawing processing on thin stainless steel materials in a cylindrical shape, pursuing roundness up to 0.08mm. 【Features】 ○ Capable of forming complex shapes ○ Forming without surface scratches is possible ○ Local thickness reduction can be minimized ○ Dimensional accuracy can be improved ○ Production process steps can be shortened For more details, please contact us or download the catalog.

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We offer smooth and beautiful deep drawing processing without cracks or cuts, even for soft materials like aluminum, which are difficult to process. When performing drawing processing with standard presses, the corners (edges) typically become 25-30% thinner. However, with Kato Manufacturing Co., Ltd.'s drawing processing technology, we can reduce the thickness decrease rate to 2-5%, allowing us to provide drawing products with uniform thickness. Additionally, the low friction during forming results in minimal surface scratches, ensuring a smooth appearance quality. 【Features】 ○ Capable of forming complex shapes ○ Forming without surface scratches is possible ○ Local thickness reduction can be minimized ○ Dimensional accuracy can be improved ○ Production process steps can be shortened For more details, please contact us or download the catalog.

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In stainless steel deep drawing processing, we can freely perform round deep drawing, challenging taper processing, and even ultra-thick drawing. We are also skilled at deep drawing of hard stainless steel, which tends to wrinkle easily. For thick materials with a thickness of 2.8mm, we have achieved cost reduction by eliminating cutting processes and mixing drawing with finishing processes. 【Features】 ○ Capable of forming complex shapes ○ Forming without surface scratches is possible ○ Local reduction of plate thickness can be minimized ○ Improvement in dimensional accuracy can be achieved ○ Production process steps can be shortened For more details, please contact us or download the catalog.

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At Kato Manufacturing Co., Ltd., we can perform drawing processes that minimize changes in sheet thickness, utilizing the "opposing hydraulic forming method" and the know-how cultivated over 30 years. Even in the drawing process of aluminum material (difficult-to-machine material) with a thickness of 1.25mm, the thickest point only increases by 1.6%, while the thinnest point decreases by 6.4%, significantly reducing variations in sheet thickness and allowing for nearly uniform drawing. 【Features】 ○ Processing can be done without surface scratches even on aluminum materials that are prone to scratching. ○ Products that could only be made through conventional machining (aircraft parts) can now be realized through special drawing processes. ○ Significant cost reductions can be achieved. For more details, please contact us or download the catalog.

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Titanium has poor formability, but conversely, it has good deep drawing characteristics. Additionally, the "Counter Liquid Pressure Forming Method" by Kato Manufacturing Co., Ltd. uses a mold that only has a punch side, allowing for high-quality processing that overcomes the issues associated with titanium processing (such as cracking, scratches, and mold seizure). **Advantages of the Counter Liquid Pressure Forming Method:** - It significantly improves the limit drawing ratio, enabling the formation of complex shapes and the processing of difficult-to-machine materials that are prone to work hardening, while also reducing the number of processes. - Due to the friction reduction effect, it allows for forming without wrinkles, cracks, or surface scratches. - The friction retention effect helps to minimize local thickness reduction of the material, allowing for uniform forming. - Since the mold only has a punch side, mold costs can be reduced. For more details, please contact us or download the catalog.

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Composite processing refers to a method that incorporates secondary operations such as tapping, welding, and assembly, which are ancillary to the subsequent processes, into press processing and performs them simultaneously. At Kato Manufacturing Co., Ltd., stainless steel materials (difficult-to-machine materials) are processed into architectural components (hardware) using a progressive die (18 stations) for press processing. However, after performing flanging processing on these components, a spot weld must be done at one point for opening prevention. Traditionally, after press processing, spot welding was done one by one by hand as a secondary operation. However, by linking the press machine with a dedicated multi-welding machine (originally manufactured), we created an automated line that synchronizes the press with spot welding, resulting in a dramatic improvement in productivity. 【Benefits of Composite Processing】 - The elimination of processes performed as secondary operations increases "added value." - Costs and space for "intermediate inventory" that would need to be stored for subsequent processes can be cut. - Since it is produced consistently as press processing, it leads to "defect reduction," including fine processing. For more details, please contact us or download the catalog.

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Plate forging technology is a technique used in press processing to create three-dimensional shapes in the height direction from plate materials. At Kato Manufacturing Co., Ltd., we process products for heat exchangers using aluminum materials (difficult-to-machine materials), and we utilize this plate forging technology at the fastening parts when fitting the upper case and lower plate together. In particular, we perform cold forging, which compresses the plate material using molds, and we have implemented processing with general press machines instead of special press machines using the swaging technique (a forming method that reduces height while simultaneously increasing cross-section by applying pressure in the axial direction). **Features of Plate Forging Technology** - Creates three-dimensional shapes in the height direction from plate materials in press processing. - Many press machines developed specifically for plate forging processing are now available. For more details, please contact us or download the catalog.

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At Kato Manufacturing Co., Ltd., we have significantly reduced costs by transitioning the manufacturing of bearing seal rings for industrial robots, made from cold-rolled steel plates (thickness 2.3mm), from traditional cutting machining to press forming (with only final finishing done through flat cutting, lathe processing, and polishing). Additionally, for motor covers made from stainless steel (difficult-to-machine material) with a thickness of 2.8mm used in home appliances, we have similarly utilized a counter hydraulic forming method that allows for uniform drawing with minimal thickness variation, as well as the ability to process thicker stainless steel in a single step. Furthermore, we meet stringent requirements for roundness of 0.012, concentricity of 0.15, and surface roughness of Ra1.6 through subsequent cutting processes, providing our customers with both cost reduction and high-quality precision. This is also made possible by achieving dimensional accuracy in press processing that is nearly equivalent to machining, leading to reduced processing time and labor in subsequent steps. 【Key Technologies for Press Forming】 - Precision cutting and punching technology - High-precision drawing technology - Plate forging technology - High-precision post-processing technology (plating, cleaning, barrel finishing, etc.) For more details, please contact us or download our catalog.

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At Kato Manufacturing Co., Ltd., we have achieved integrated molding of stainless steel (difficult-to-cut material) exhaust pipe ducts for construction, with a plate thickness of 0.8mm, by connecting the conventional round shape of the pipe and the square shape of the exhaust outlet. This was accomplished using our unique deep drawing technology. The process requires advanced techniques as it involves simultaneously forming round and square shapes in one step, which can easily lead to material protrusion, wrinkles, and cracks. 【Features】 - Our 30 years of experience with opposing hydraulic forming methods allows for process shortening. - We can address issues of galling while also accommodating difficult and high-precision molding. - Fully capable of handling difficult-to-cut materials such as stainless steel. For more details, please contact us or download the catalog.

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Recently, many superalloys with excellent heat resistance, corrosion resistance, oxidation resistance, and high-temperature properties have been developed. At Kato Manufacturing Co., Ltd., we have positioned press processing utilizing these alloys, which are said to be difficult to machine due to their high machinability challenges, as one of our specialized technologies, and we have been working on product development together with our customers. 【Various Heat-Resistant Alloys】 ○ Inconel (heat-resistant alloy) ○ Hastelloy (corrosion-resistant and heat-resistant alloy) ○ Pure Nickel (corrosion-resistant alloy) For more details, please contact us or download the catalog.

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In press processing, it is common for many defects, including breakage, to occur during molding. To better understand the characteristics of aluminum and grasp the forming limits, we applied deep drawing technology at our test center by arranging different heights of irregular drawing in parallel to investigate and verify the forming limits where breakage occurs. Through repeated testing, we believe that the know-how of Kato Manufacturing Co., Ltd.'s drawing processing technology has further improved, allowing us to respond broadly to a wide variety of customer requests. We expect that Kato Manufacturing's test center will continue to serve as a high-tech base that meets your expectations and can be utilized for various purposes such as development, testing, and prototyping. 【Classification of Press Forming and Characteristics of Deformation】 ○ Deep Drawing Deformation ○ Bulging Deformation ○ Stretch Flange Deformation ○ Bending Deformation For more details, please contact us or download the catalog.

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At Kato Manufacturing Co., Ltd., we process products using soft magnetic materials (Permalloy) through press processing, ensuring a combination of high-precision punching and high-precision bending. We achieve a general punching tolerance of plus or minus 0.05 mm and a bending angle tolerance of zero plus 0.1 mm, establishing a mass production system. Particularly, since Permalloy is a very expensive material, the occurrence of defective products is not permitted. Therefore, high reliability in molds and long-lasting processing are required. **Characteristics of Permalloy** - Low coercivity and high permeability - Used in magnetic cores for coils and transformers, magnetic yokes, magnetic shields, etc. - Has the ability to easily respond to slight changes in magnetic fields For more details, please contact us or download the catalog.

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At Kato Manufacturing Co., Ltd., we use tough pitch copper with reflow tin plating to press parts called lead frames, which support and fix semiconductor elements (semiconductor chips) used in semiconductor packages such as ICs and LSIs, and connect them to external wiring. When pressing the plated copper sheets, due to the material characteristics of having a hard surface and a soft interior, the mold punch is prone to seizing, requiring careful selection of mold materials and lubrication. Additionally, because there are terminal components that resemble centipede legs, as well as numerous burr processing and pilot hole processing of similar thickness to the sheet, special measures are necessary to prevent scrap and punch breakage, and high-level technology is required to meet the quality demands of all holes and terminal parts. 【Characteristics of Tough Pitch Copper】 ○ Copper alloy number: C1100 ○ Composition: Cu 99.90 or higher ○ Tensile strength: 245–315 N/mm² ○ Elongation: 15.0% ○ Hardness: 75.0–120.0 HV For more details, please contact us or download the catalog.

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