三光合成 List of Products and Services

We would like to introduce the "molding technologies" that we employ within our group. We utilize various molding technologies, including "decorative molding," which allows for decoration on cover shapes with deformable PL, "stack molding," which is suitable for symmetrical products, and "high-cycle molding," which realizes a total system from design to molds, molding, and equipment. Please feel free to contact us when you need our services. 【Molding Technology Lineup】 ■ Hollow Injection Molding (Gas Injection Molding) ■ Decorative Molding (Thermoject Molding) ■ Stack Molding ■ High-Cycle Molding ■ Multi-color Molding *For more details, please refer to the PDF materials or feel free to contact us.

• Blow Molding Machine

Sankoh Gosei has in-house mold factories in Japan, India, and the UK, and procures molds worldwide from various business locations. Additionally, engineers from Sankoh Gosei, primarily based in Japan, serve as supervisors for new model development projects in factories around the world. In particular, for mold procurement from China, mold design engineers and mold finishing technicians are dispatched to the China office. They are responsible not only for arranging molds but also for verifying designs based on mold assembly drawings, checking the quality of molds on the manufacturing floor, conducting measurement checks, and overseeing prototype production, ensuring responsible procurement of molds from China. [Features] ■ Mold production: 3 locations (3 countries) ■ Mold procurement: 10 locations (8 countries) *For more details, please refer to the PDF materials or feel free to contact us.

• Mold Design

We would like to introduce "CAE analysis technology" from Sanglobe. By utilizing flow analysis, we reduce the size of molding machines and perform warpage analysis on molded products that are expected to deform, reflecting this in the mold. By predicting product deformation and creating molds accordingly, we can reduce the number of mold modifications and costs. By using analysis to anticipate mold shapes in advance, we achieve reductions in startup time and costs. 【Features】 ■ Introduced CAE in 1986 ■ Accumulated utilization technology in a database ■ Developed independently for issues that cannot be addressed with commercial software ■ Extensive analysis track record (a total of 5,171 cases) ■ Reduced molding machine size by utilizing flow analysis ■ Conducted warpage analysis on molded products expected to deform and reflected this in the mold *For more details, please refer to the PDF document or feel free to contact us.

• Contract Analysis
• Other analyses
• Contract Analysis

Typically, when conducting CAE, the model is mostly in STEP/IGES format. In this format, the dimensions of the model are included, and the surfaces are not distorted. Therefore, the coordinate system can be easily created. However, in solid analysis, it is necessary to reproduce the deformation of the model, so it is automatically converted from STEP format to point cloud STL format. This means that the dimensions and surfaces that the model had will be distorted. In this case, there is not even a reference surface, let alone a coordinate system. Thus, it is necessary to virtually create a reference surface and define it as the reference surface. Measurements are conducted not only in the analysis but also on actual molded products on surfaces that have been virtually created in the same way. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

In general, a plane is calculated using the cross product of vectors that pass through three points, resulting in the plane equation ax + by + cz + d = 0. However, in actual measurements, it is rare to create a plane from just three points. This is often because product drawings typically instruct to create a reference plane from four or more points. When creating a plane from more than four points, the coefficients of the plane equation are determined using the least squares method. However, the measurement points cannot be arbitrary. Creating a reference plane in measurements can be considered an important process for determining the acceptability of a product. *For more details, please refer to the related links or feel free to contact us.*

• 3D measuring device
• Other measurement, recording and measuring instruments

This time, we will introduce commonly used methods for measuring and creating circles. Basically, a circle can only exist on a single plane. However, actual products have 3D shapes, and if they are warped or deformed, it can be quite difficult to select points that lie on the same plane. If a point not on the same plane is mistakenly selected, it is likely that the measurer will not realize it. So, how can we select points on the same plane? One method is to use a function called "projection." This allows us to forcibly place the selected point onto a chosen surface, ensuring that it exists on the same plane. In this method, the accuracy of the reference plane creation can significantly affect the measurement results. Furthermore, when measuring a circle, taking points at equal angles will yield more accurate measurements. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

CFRP can be molded by pressing an intermediate material called prepreg. There are two types of prepreg: one that has fibers oriented in two directions using plain weave or twill weave, and another that has fibers oriented in only one direction (UD). The prepreg with plain or twill weave has half the fiber orientation compared to the one-directional prepreg, resulting in approximately half the strength. By changing the stacking pattern of CFRP, not only the strength but also the manner of failure can be altered. To find the appropriate stacking method according to specifications, it is necessary to accumulate verification through experiments. *For more details, please refer to the related links or feel free to contact us.*

• Composite Materials

The density changes when the molten resin solidifies. When the molten resin solidifies, the volume usually decreases compared to the molten state. If the entire product shrinks evenly at a constant rate, the molded product will simply become smaller, maintaining a similar shape. However, if the shrinkage varies in different parts, the molded product will deform and change shape, making it impossible to achieve the desired shape just by adjusting the dimensions of the mold. The deformation of the product is believed to be caused not by some external force acting on it, but by the distribution of partial strains leading to overall deformation. This way of thinking is used as a phenomenon model in the calculations for shrinkage warpage analysis in injection molding CAE (Computer Aided Engineering). *For more details, please refer to the related links or feel free to contact us.*

• Resin mold
• Other analyses

Hot runners eliminate the need for unnecessary runners during molding because the gates are always molten. However, this means that material remains in the runner at all times. If you try to mold a different color resin using the same hot runner, what happens is that if the previously molded material was black, switching to beige will still leave black resin behind, resulting in defective products. To resolve this issue, it is necessary to discard 20 to 30 molded products, which poses significant challenges in terms of both environmental impact and cost. Therefore, we began the development of the Twin Way Valve Gate (TWVG), which can switch between two different types of materials in one go. *For more details, please refer to the related links or feel free to contact us.*

• Other molds

Due to the structure of the hot runner, it is almost impossible to change the color of the resin in one shot through the same flow path. So, if we use different systems, wouldn't it eliminate the need for color change? Based on this concept, we developed a valve gate system with two independent flow paths. To switch the flow path system, it is necessary to set up a dedicated nozzle switch. This allows for the color change of the resin in one shot. *For more details, please refer to the related links or feel free to contact us.

• nozzle

To change the color of the hot runner in one go, the flow path system of the hot runner is made independent, and the nozzle is made switchable. To achieve this, the nozzle switching has been designed to be slide-operated for control. By making it slide-operated, the switching of the resin can be carried out smoothly. 【Hot Runner Resin Flow Path】 ■Nozzle A: Flows with forward slide ■Nozzle B: Flows with backward slide *For more details, please refer to the related links or feel free to contact us.

• nozzle

"Stack molding" refers to a molding process that allows for doubling the number of products produced with the same clamping force as a standard mold by using a two-tiered mold structure. The production quantity per molding shot is doubled, and the total projected area of the products is reduced to half, making it possible to lower the tonnage of the molding machine. Additionally, the cost of the mold is generally lower compared to the case of producing two standard molds. 【Advantages】 ■ The production quantity per molding shot is doubled. ■ The total projected area of the products is halved, allowing for a reduction in the tonnage of the molding machine. ■ The cost of the mold is generally lower compared to the case of producing two standard molds. *For more details, please refer to the related links or feel free to contact us.

• Other molds

In CAE, calculations are not performed using the 3D data itself, but rather by replacing it with elements called meshes to calculate deformation and stress. It is said that the finer the mesh, the higher the accuracy of the deformation and stress calculations. Meshes come in various shapes and sizes, but in 3D shapes, hexagonal meshes and tetrahedral meshes are the two main types. Hexagonal meshes are composed of hexahedra and are said to have high calculation accuracy. Tetrahedral meshes are composed of tetrahedra, and while their calculation accuracy is inferior, they provide a higher degree of shape reproduction. Therefore, in analysis settings, we aim to create meshes using hexagonal types whenever possible, and if that is not feasible, we switch to tetrahedral meshes to proceed with the work. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

In CAE, hexahedral meshes are considered to have high analysis accuracy, while tetrahedral meshes are known for their high shape reproduction capability. However, under conditions where the model undergoes relatively large deformations (large deformations), tetrahedral meshes may exhibit better shape reproducibility and analysis accuracy than hexahedral meshes. The Poisson's ratio of rubber is generally considered to be 0.5, making it an incompressible material. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

In CAE, it is said that the finer the mesh size, the higher the analysis accuracy. However, depending on the boundary conditions and model shape, a mesh that is too fine can sometimes actually decrease analysis accuracy. This is known as the existence of "singularities." These are likely to occur in areas where the corner radius is zero or very small. If the stress continues to increase as the mesh size is reduced, it is advisable to suspect this "singularity." Therefore, instead of judging based on the maximum stress at the location with a zero corner radius, it is better to evaluate the stress at a slightly offset location. Additionally, if possible, it is recommended to add a sufficiently large corner radius at the zero corner radius locations and conduct a re-analysis. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

When independent models are in contact or very close to each other in CAE, contact conditions are automatically assigned in the CAE settings (in the case of ANSYS). By setting these contact conditions, even if one model moves or is subjected to a load, it will not penetrate the other model. The contact conditions are mainly "bonded contact," but there are also settings such as "no separation" and "rough." *For more details, please refer to the related links or feel free to contact us.*

• Other analyses

Many resins have properties in both the elastic region and the plastic region. In the elastic region, the strain returns to zero when the stress is removed, resulting in linear behavior. However, in the plastic region, the strain does not return to zero when the stress is removed, leading to nonlinear behavior. To perform calculations in the nonlinear region during structural analysis, it is necessary to input material properties. However, inputting properties for the nonlinear region requires entering strain values for each stress point, which is quite cumbersome. Additionally, the computation time becomes longer. To simplify the input of material properties, we use a method called "two-line approximation" to shorten the computation time. This approach replaces the properties of the resin from the yield point to the fracture point with a single straight line (tangent modulus). This method is particularly suitable for quickly checking design values in models with a large number of elements and significant computational scale. *For more details, please refer to the related links or feel free to contact us.*

• Structural Analysis

Our company has increasingly been utilizing resin flow analysis for product launches. However, if the analysis indicates that the deformation does not remain within the target amount, we will need to reconsider the product shape. That said, there are often cases where the product shape cannot be significantly altered due to specifications. Furthermore, even if we were to make substantial changes to the product shape, we cannot guarantee that it would remain within the target deformation amount. As a solution, our company is implementing "inverse warpage analysis" as one approach to effectively utilize analysis results and reconstruct models. Currently, there are requests to apply this to certain automotive parts, and we are considering its application to various automotive components in the future. *For more details, please refer to the related links or feel free to contact us.*

• Other analyses
• Analysis Services

Our company introduced "Mold Flow" in-house in 1986. Since then, we have independently collected resin data and accumulated reliable 'CAE analysis examples' using our own know-how. We have conducted over 1,800 analysis cases. Using in-house measured resin data, we have developed our own rheometer to measure the flow characteristics of resins. [Features] ■ Introduction of "Mold Flow" in-house ■ Over 1,800 analysis cases conducted ■ Development of our own rheometer for measuring resin flow characteristics *For more details, please refer to the PDF materials or feel free to contact us.

• Contract Analysis

We have summarized the molding technologies and considerations related to the underpanel that covers the underside of the automobile. As requirements for the "preliminary study," "stress analysis," "frequency response," and "thermal analysis" are mentioned. In the related links, we also introduce "manufacturability studies," "mass production systems," and "quality assurance." 【Preliminary Study】 ■ Requirements - Stress analysis, frequency response, thermal analysis ■ Manufacturability Studies - Used resins, product shapes, PL settings, runner settings (flow analysis) - Block molding technology, gas vent design, resin flow analysis *For more details, please refer to the related links or feel free to contact us.

• Stress Analysis
• others

At our company, it is common to use steel materials such as S55C when creating molds. However, for small production runs or depending on the product shape, we can also propose the use of aluminum molds for production. The advantages of aluminum molds include "shortened delivery times" and "reduced factory equipment due to their lightweight." Complex shapes can also be reproduced. Please feel free to contact us when you need assistance. 【Advantages of Aluminum Molds】 ■ Shortened delivery times (reduced time for cutting, polishing, and electrical discharge machining) ■ Cost reduction for molds compared to general steel materials ■ Lightweight, allowing for reduced factory equipment ■ Excellent thermal conductivity, leading to efficient cooling times → possible reduction in molding cycles ■ Good fluidity of resin, making it easier to suppress shrinkage *For more details, please refer to the related links or feel free to contact us.

• Other molds
• aluminum

The global network of Sango Composite supports your work. We assist you in conducting business without any regard for borders, whether you are a customer in Japan or overseas. For example, we arrange parts for delivery to overseas factories in Tokyo, design molds produced in China in Toyama, and introduce new technologies developed in the UK to Japan... Utilizing our worldwide mold procurement network centered around our technical centers in Japan, we propose cost-effective and time-efficient planning, design, production, and delivery methods. We have 18 production sites and 2 mold factories overseas. We have been expanding globally with the concept of "producing close to our customers." Please feel free to contact us when you need assistance. 【Domestic Bases in Japan (Partial)】 ■ Production Factories - Toyama Prefecture (Headquarters) - Gunma Prefecture - Shizuoka Prefecture - Shiga Prefecture - Saitama Prefecture - Oita Prefecture ■ Mold Factories - Technical Center - S-Bounce *For more details, please refer to the related links or feel free to contact us.

• Plastic Mould
• Mold Design
• Other molds

In the plastic industry, "texturing" refers to the process of performing physical surface treatments on the mold surface, such as etching or sandblasting, and transferring that surface onto plastic. It can also transfer patterns similar to those found in leather products, which not only adds a sense of luxury but also makes the texture more pleasant to touch, prevents slipping, and makes dirt and scratches less noticeable. Moreover, when considering the injection molding process, larger products tend to be molded with multiple gates, which can make weld lines and sink marks more prominent. By applying "texturing," these patterns become less visible, making it a truly two-for-one molding technique. *For more details, please refer to the related links or feel free to contact us.*

• Other surface treatment equipment

Our company has been measuring resin shrinkage rates using dedicated molds for over 20 years to determine the shrinkage rate of molds. The resin shrinkage rate varies depending on molding conditions and wall thickness. By measuring from actual products rather than relying on catalog values, we can obtain data that is more committed to the molding site, contributing to the reduction of defect rates in molds and products.

• Calibration and repair
• Other contract services

Sanglory Co., Ltd. is engaged in initiatives for automatic 3D mold design, starting with concurrent engineering that consistently utilizes 3D data, as well as efforts towards new processing technologies. We aim to shorten lead times, reduce costs, and improve quality through the introduction of new processing machines and tools, including 5-axis machining centers, and by utilizing our self-developed unmanned machining programs. [Initiatives in Mold Design and Manufacturing] ■ Shortening lead times ■ Cost reduction ■ Quality improvement *For more details, please refer to the PDF materials or feel free to contact us.

• Mold Design

We would like to introduce our company's initiatives in carbon fiber. At "Dream Workshop," we are working on the development of molding technologies that leverage the strength of carbon fiber, with the capability to mold in two types: thermoplastic and thermosetting. Please feel free to consult us for prototypes and mass production. 【Features of our carbon fiber molding】 ■ Short molding cycle ⇒ Pre-molding in the mold before compression molding ■ Strong strength of molded products ⇒ Increased internal pressure during molding leads to improved resin impregnation ■ Reduced burrs ⇒ Prevention of resin leakage using PL cooling method *For more details, please refer to the PDF document or feel free to contact us.

• fiber
• Other molds
• Processing Contract