プラスエンジニアリング List of Products and Services

This is an example of a chip processed product with fine knurling. Compared to a one-yen coin, the chip size is about the size of a fingertip, making it very difficult to grasp. This fine processed product has various applications, including material joining and medical instruments represented by tweezers. There are multiple methods for this knurling, but this one is finished using grinding with a grinding wheel, allowing for a smooth surface finish. The pitch accuracy is also at the micron level, providing excellent precision. Although the peaks can chip or flatten if bumped, we manage the peaks and valleys to ensure they are well-defined and the tips do not get flattened during processing. 【Production Example】 ■Material: Carbide ■Product Size: T0.8×3×2 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a tool used in a special joining method called friction stir welding (FSW). During FSW, such tools are used, and the protruding parts that come into contact with the product require high concentricity and a smooth surface finish. Since the joining method itself involves quite a demanding application, tools made from high wear-resistant tool steels, such as high-speed steel, are necessary for durability. Additionally, DLC coating is applied to improve tool life. If a lower cost finish is acceptable, there is a method to complete the tool using a CNC lathe, sacrificing some precision. However, if precision and surface finish are prioritized, high-quality results can be achieved by performing profile grinding to neatly shape the R part of the tip. 【Production Example】 - Material: SKH51 (DLC Coating) - Product Size: φ12×90 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a case of an ejection pin designed to eject resin-molded products from a mold, made of ultra-hard alloy to withstand wear even after being used repeatedly over tens of thousands of times. The outer diameter dimension tolerance is specified as ±2μm, but due to the large length relative to the diameter, such grinding processes can lead to the item escaping and make it difficult to achieve concentricity. There are also stringent requirements for geometric tolerances such as straightness tolerance. Our company possesses various grinding machines and responds with grinding methods suited to the shape and material. [Production Example] - Material: General wear-resistant carbide - Product Size: φ3.6×L75 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a part called a core pin used in the molding of connectors. During the molding of connector components, this pin is inserted into the mold for shaping, and even such fine pins are designed with materials that can withstand repeated use. This core pin is actually used at a length of about 6 millimeters from the tip, and the root's shape is designed to accommodate the profile processing grinding wheel. By using a smaller diameter grinding wheel, the R size of the shape can be minimized, allowing for the precision machining of such fine pins through grinding. The tip is only 0.4 millimeters square, yet it has a precision of ±0.003 and features a step, showcasing the strengths of profile processing. 【Manufacturing Example】 ■Material: HAP10 (Powdered High-Speed Tool Steel) ■Product Size: 4×4×53 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a dispenser nozzle with an inner diameter of φ0.06 small hole. When such a small diameter nozzle is used continuously under high pressure, there are cases where it does not last long. However, because this product is made from ultra-fine particle carbide, it can achieve a lifespan several times that of steel, depending on the conditions. The inner diameter is finished with fine hole electrical discharge machining, which is one method of creating fine holes in hard alloys that cannot be processed with cutting tools. Fine hole discharge machining involves rotating the electrode to create the hole, but since the electrode diameter is even smaller than the hole diameter, it requires skill to achieve high precision. [Manufacturing Example] - Material: Ultra-fine particle carbide - Product Size: (Tip) Inner diameter φ0.06, Outer diameter φ0.15 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a part made using SKD11. This cutter has 64 holes with a diameter of φ0.73, and it is designed to cut the product at the hole sections. It is necessary to uniformly create the hole diameter precision (tolerance range of 0.01mm) for all 64 holes. Our company utilizes various machining processes, such as machining and wire electrical discharge machining, according to the requirements (hole diameter, diameter precision, etc.) to perform such a large number of hole processing. SKD11 is a material suitable for precision machining, as it undergoes hardening under specific heat treatment conditions, resulting in very little dimensional change due to heat treatment. This makes it useful for tools that are prone to warping. [Production Example] ■Material: SKD11 ■Product Size: 150×25×20 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a part that has been finely processed with micro-patterning on a carbide material, which is one of the related components for semiconductor manufacturing equipment. Performing fine processing on carbide, which does not hold an edge, is accomplished through profile grinding, which specializes in fine groove processing. "Profile" originally refers to the contour, but profile grinding is a process where the contour is projected onto a projection plate magnified about 50 times, allowing for precise positioning and grinding. The shape of the protrusions at the micron level can be accurately finished through such high-precision grinding. [Production Example] - Material: General wear-resistant carbide - Product Size: 35×20×3.5 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a part made using ultra-fine particle carbide. Generally, carbide alloys referred to as fine or medium grain have particle sizes of several microns or more, while ultra-fine particle carbide has a particle size of less than 1 micron. Although finer particle sizes reduce impact resistance, they provide exceptional wear resistance. Due to the very long cutter, the part used as the blade is approximately 200mm long. As a result, although the structure is simple, achieving the precision needed to control the warping of the blade is very difficult. Additionally, high-level skills are required for grinding processes to ensure that chipping does not occur on any part of the cutting edge. [Production Example] - Material: Ultra-fine particle carbide - Product Size: 205×16×5 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of using high-speed tool steel (SKH51). It is a material frequently used for cutting tools. Among tool steels, it has particularly high hardness (HRC 64 or higher) and excellent wear resistance, but care must be taken to avoid chipping of the cutting edge when used for such thin (0.5mm thick) cutters. Due to its shape resembling a saw blade, it cannot be processed using the flat grinding machines typically used for cutter manufacturing. Our company processes this shape using profile machining. 【Production Example】 ■Material: SKH51 ■Product Size: 60×20×0.5 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is an example of a cutter made from general-purpose carbide. The part used as the blade has a flat edge at the tip with a width of 0.1. The key point is to finish this tip edge accurately and with good sharpness. It is said that the sharper and thinner the cutting edge of the cutter, the better the cutting performance. On the other hand, a sharp cutting edge is more prone to chipping and tends to have a shorter lifespan. By providing a slight flat surface at the tip, as in this part, the lifespan of the component can sometimes be improved. 【Production Example】 ■ Material: General wear-resistant carbide ■ Product Size: 5×2×1.2 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a case study of an aluminum motor case production. In prototype machining for testing the product's functionality, requirements such as material, dimensional accuracy, and surface finish are necessary, which makes machining from raw materials essential. This part is an example of cutting processing using a machining center, but even for shapes and materials that are difficult to process with machining, our company has a variety of processing machines available, allowing for alternative processing methods. Additionally, since we perform integrated processing in-house, we can process using methods that are suitable for the shape and accuracy. 【Production Case】 ■Material: Aluminum (A5052) ■Product Size: 60×90×90 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a machining example where the axis on the tip side is eccentric from the central axis. The amount of eccentricity of the axis at the tip from the central axis is 3mm. On the eccentric tip side, there is a groove processing with a width of 0.5mm, a depth of 0.5mm, and a pitch of 1mm on the outer circumference of φ7mm, as well as a taper processing towards the tip φ3. The axis, except for the tip part, is aligned at the center but has a rounded corner composite shape, and an iris rosette m=0.3 is machined at the tip on the opposite side of the eccentric part. Our company performs integrated processing in-house using various machining machines, allowing us to process harder materials and manage quality for difficult machining tasks, adapting to the required precision and intended use. 【Production Example】 ■Material: Aluminum alloy ■Product Size: φ18×L46 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

We would like to introduce a case study on cost reduction in setting precision standards. For holes in square-shaped parts, costs can vary significantly depending on how the reference surfaces (points) are determined. By changing the drawing instructions, we can greatly reduce the processing man-hours. By altering the method of determining the reference surfaces in the drawing dimensions, we can improve the grinding process by measuring from two outer diameters. Additionally, by incorporating reference holes during the design phase, it is also possible to design in a way that eliminates the need for outer diameter grinding altogether. *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

We will introduce the points of cost reduction design through the utilization of center holes. When the dimensional tolerances and geometric tolerances of the cylindrical outer diameter are strict and grinding finish is required, a chuck boss is necessary for setting on the cylindrical grinding machine. Additionally, this boss will need to be cut off after the cylindrical grinding is completed. By allowing center holes on both end faces, it becomes possible to set the workpiece on the cylindrical grinding machine using center support, eliminating the need for a chuck boss. This can lead to a cost reduction of approximately 20% through savings in material costs and labor hours. *For more details, please refer to the PDF document or feel free to contact us.*

• Contract manufacturing
• Processing Contract

This is an example of thin-walled jig processing used for product assembly. Originally made from SUS303, it was selected to use SUS316 as the material to withstand more corrosive environments. First, the entire piece is made into a cylinder using a CNC multi-tasking lathe, while simultaneously machining the window section from the side. The protruding part that remains at the bottom, resembling a claw, particularly requires shape accuracy, but there is a risk that the item may deform due to machining stress when being cut with tools. The claw section is prone to distortion when machined with cutting tools, but by utilizing wire electrical discharge machining, which applies different machining stresses, a high-precision finish can be achieved. [Production Example] - Material: SUS316 - Product Size: φ63×L40 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a multi-stage pin with a general CN-X coating (Matsuyama Giken Co., Ltd.). It is a multi-stage pin with a geometric tolerance of 0.01 for core runout, and the adopted tolerance range is 0.01mm. For such components, skilled cylindrical grinding techniques are required. The selection of grinding wheels and the management of the tips of the grinding wheels determine the precision of this component. Especially for parts that undergo PVD coating, the surface condition before coating affects the adhesion (lifespan) of the coating film. 【Production Example】 ■Material: General wear-resistant carbide (CN-X coating) ■Product Size: φ15×L96 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a flange (φ50) made from nickel alloy Kovar. While cutting tools can quickly become damaged and machining can be difficult, our company is capable of processing with a beautiful surface finish as shown. The polishing marks from the iris polishing that occur when polishing a recessed surface, as well as the flat surface polishing of the thickness, are also beautifully finished. Almost all outer diameters are finished by polishing, and since multiple grinding methods are used, you can see the differences in the finish of the machined surfaces. 【Production Example】 ■Material: Kovar ■Product Size: φ50×L18 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a case study of manufacturing aircraft parts using Hastelloy. Hastelloy is a type of nickel alloy, with the addition of molybdenum and chromium, which provides excellent oxidation resistance at high temperatures. Although it is difficult to machine, it can be smoothly finished using a composite lathe. It can also be easily finished with angled holes and taper machining. 【Case Study】 ■Material: Hastelloy X ■Product Size: φ195×L40 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This product is used as the spindle for grinding wheels in grinding machines, requiring a dimensional accuracy of 0.005 or less for the cylindrical outer diameter and a coaxiality of 0.01 or less. Additionally, the flange part, which serves as the mounting reference surface, and the cylindrical surface require a perpendicularity accuracy of 0.005, necessitating finishing by cylindrical grinding for both the flange reference surface and the outer diameter. To achieve high precision finishing through cylindrical grinding, the key point is how to hold the workpiece without any runout on the cylindrical grinding machine. In this case, high-precision center holes are machined on both end faces, and the workpiece is held using a tailstock for high-precision machining. Furthermore, to ensure such precision machining, we have introduced roundness measuring instruments and are also working on guaranteeing geometric tolerances reliably. 【Production Example】 ■Material: SCM435 ■Product Size: φ86×L180 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

This is a shaft made using 64 titanium. It has the lightweight properties of aluminum while possessing strength comparable to steel, making it widely adopted for various mechanical components. 64 titanium contains 6% aluminum (Al) and 4% vanadium (V) by mass, providing a good balance of strength and toughness. It is a material with high ductility, and the finishing of the threaded part at the tip can be smoothly achieved through turning processes. In particular, our company has improved the machinability of such difficult-to-cut materials through low-frequency vibration cutting using Citizen Machinery's automatic lathes, which we introduced in recent years. 【Production Example】 ■Material: 64 Titanium Alloy ■Product Size: φ6×L60 *For more details, please refer to the PDF document or feel free to contact us.

• Contract manufacturing
• Processing Contract

Our company has the technology for "molybdenum-impregnated anodizing treatment," which deposits molybdenum disulfide onto a hard anodized coating. By depositing molybdenum disulfide, we reduce the friction coefficient and decrease adhesive wear. Additionally, molybdenum disulfide maintains lubrication at high temperatures and is effective in preventing seizure. 【Features】 ■ Lubricity ■ Heat resistance ■ Corrosion resistance ■ Wear resistance ■ Insulation, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company handles the technology of "hard chrome plating," which has expanded its application range to high-precision machine parts used in implementation assembly devices, semiconductor assembly devices, and molding dies. Due to its wide range of applications and the ability to re-plate without damaging the base material, it is adopted in various fields of precision machine parts. Please feel free to contact us if you have any inquiries. 【Features】 ■ High hardness: HV800–1200 ■ Wear resistance: The sliding coefficient of chrome-steel is 50% of steel-steel ■ Adhesion: Almost alloyed with the base material, preventing peeling ■ Heat resistance: No discoloration below 400℃ ■ Corrosion resistance: Not affected by chemicals, with a purity of 99.998%, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company offers a "hard anodizing - fluorine composite treatment" that forms an oxide film through hard anodic oxidation treatment of aluminum or aluminum alloys. This surface treatment is effective for providing wear resistance, release properties, corrosion resistance, and electrical insulation by impregnating fluororesin into a porous surface. 【Characteristics】 ■ Applicable materials: Aluminum or aluminum alloys However, alloys containing more than 5% Cu and more than 7% Si are excluded. ■ Film thickness: Standard thickness of 20 to 50 μm, determined by material type and intended use. ■ Hardness: Typically HV200 to 450, but varies depending on the type of substrate and film thickness. ■ Electrical insulation: Non-conductive with good insulation properties. With film thickness, withstand voltage is 500 to 1000V. ■ High and low-temperature characteristics: Stable properties in environments ranging from -200℃ to +220℃, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company possesses technology for "black chromium oxide surface treatment," which has excellent corrosion resistance and is particularly applied in the field of precision electronic devices, especially semiconductor manufacturing equipment. It can withstand temperatures from -260 to 360°C, and due to the low-temperature processing, there is no thermal impact on the base material. Additionally, because it is a thin film, post-processing after finishing is possible. 【Features】 ■ Treatment film thickness: 1–2μm: post-processing after finishing is possible due to the thin film ■ Treatment temperature: low-temperature processing ■ Matte finish surface heat collection effect ■ Conductivity (resistivity: 70Ωcm) ■ Optical halation countermeasures, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company handles the technology of "Vacuum Gas Nitriding Treatment," which utilizes the diffusion principle of nitrogen atoms through a vacuum furnace. In a vacuum furnace, NH3 and nitriding-promoting gas are introduced, and the temperature is heated to 480-550°C. The heating state is maintained to allow nitrogen to diffuse into the base material, generating alloy elements and compounds as a surface treatment method. 【Features】 - No brittle white layer, preventing defects and peeling of the hardened layer - Minimal dimensional changes such as warping and expansion - Surface roughness remains almost unchanged from before treatment, achieving a good mirror finish - Excellent wear resistance - Uniform hardening even in complex shapes, deep holes, and fine wires, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company offers "High-Density Ultra-Fine Diamond Sintered Bodies," which achieve a significant increase in hardness by sintering ultra-fine diamonds at high density. We have made the diamond layer (hard layer) of the diamond sintered body thicker, expanding its applications as a component. Additionally, we minimize the reduction in wear resistance, achieving approximately 50% faster wire-cut electrical discharge machining compared to conventional methods. 【Features】 ■ A wide range of Vickers hardness from 3500 to 7500 (kgf/mm²) available for various applications ■ Improved toughness ■ Custom non-magnetic diamond sintered bodies compatible with electronic devices available *For more details, please download the PDF or contact us.

• Other polymer materials

Our company possesses the 'DLC coating' technology, which is actively adopted in semiconductor IC bending mold components, electronic components, sliding parts, and has been effective. The industrial application of 'DLC coating' features low surface roughness and friction coefficient, excelling in sliding properties, and is widely applied in electronic components, precision machine parts, molds, and cutting tools. 【Main Features】 ■ Corrosion resistance: Does not dissolve in acids or alkalis ■ Wear resistance: Hv1500–2500 ■ Low friction coefficient: 0.05–0.2 without lubrication ■ Release properties: Reduced adhesion and seizing of soft metals ■ Smooth film: Does not compromise the smoothness of the substrate, etc. *For more details, please download the PDF or contact us.

• Surface treatment contract service

We offer a "conductive anodic oxidation treatment" that achieves a film with an electrical resistance value of approximately 10^6 to 10^8. Anodic oxidation treatment involves using the metal as the anode to electrolyze an electrolyte solution, forming an oxide film on the surface of the anodic metal. Furthermore, through secondary electrolysis, metal ions are electrically introduced into the porous oxide film formed on the surface of aluminum and aluminum alloys, combining with aluminum oxide to create a composite film. 【Optimal Material Types】 ■ JIS Aluminum Alloy Extrusions - A1000 series, A2000 series, A5000 series, A6000 series, A7000 series *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company offers "composite ceramic surface treatment" as a surface treatment technology to improve wear resistance, surface hardening, and reduce friction coefficients. A thick coating is formed by adding fine ceramic particles to a chromium oxide base on the substrate, creating a hard composite ceramic layer. 【Applicable Materials】 ■ Carbon steel, stainless steel, alloy steel ■ Titanium alloys ■ Chromium alloys ■ Nickel alloys *For more details, please download the PDF or contact us.

• Surface treatment contract service

Our company offers a technology called "Electroless Nickel-Fluororesin Surface Treatment," which involves impregnating a hard, porous nickel-phosphorus alloy coating with a non-stick, heat-resistant fluororesin. Not only does the coating have high hardness, but it can also meet needs related to the mechanical strength of the material, heat resistance, slip and release properties, water repellency, and resistance to dirt. 【Features】 - A composite film that maintains wear resistance, slip resistance, seizure resistance, non-stick properties, weather resistance, and oil resistance, with strong adhesion to the base material. - Uniform coating coverage and good dimensional accuracy in finishing, among other benefits. *For more details, please download the PDF or contact us.

• Surface treatment contract service