ゼン List of Products and Services

Zen Corporation is a comprehensive prototype manufacturer that meets all prototype needs, from resin processing and metal processing to surface treatment. With 45 years of experience, we propose optimal processing methods based on the prototype know-how cultivated through transactions with various industries. We also respond to difficult requests that are challenging for other companies, leveraging our experience and track record. Additionally, we are highly regarded for allowing design and development personnel to place orders with confidence, as they can confirm the flow of prototypes, the fitting of each part, design changes, and more while work is in progress. **Business Activities** - Manufacturing prototype parts for precision instruments, electronic components, office machines, and other plastic and metal products - Design and manufacturing of molds - Design and manufacturing of process jigs and prototype jigs - Three-dimensional modeling services - Three-dimensional measurement services *For more details, please refer to our catalog or feel free to contact us.*

• Prototype Services

If there are no issues with the processing method of the prototype, we also accept parts production for small lot manufacturing. In addition to simple molds, we support parts production through various processing methods, including resin processing and metal processing.

• Processing Contract

We have specialized staff for tooling, so we design and manufacture original tools and jigs from the planning stage based on our customers' requirements. We have a wealth of production experience with various types of fixtures, including fixed jigs, cutting jigs, insertion jigs, assembly jigs, inspection jigs, and measuring tools. We utilize the know-how cultivated in various industries to create the tools and jigs that meet your needs. Regarding production, we conduct meetings with the representatives from the production department and the production technology department, along with our sales and jig department personnel, to make various proposals and complete the project, ensuring that we deliver better jigs to our customers.

• Prototype Services
• Contract manufacturing
• Machinery and equipment installation/dismantling/relocation

We manufacture custom-made devices ranging from equipment for conducting durability tests on prototypes to devices aimed at streamlining operations. We have a wealth of production experience in quality inspection equipment, performance evaluation devices, labor-saving machinery, and inspection machines. Engineers with extensive knowledge in areas such as "mechanical design," "electrical design," "3D modeling," "embedded programming," and "electrical work" will work closely with you from the conceptual stage to create the device you desire. We will turn your request of "I want to create something like this" into reality.

• Other FA equipment

This is a representative processing method of Zen. The characteristic of resin cutting processing is undoubtedly its excellent processing accuracy. Additionally, the ability to use materials that are very close to those used in mass production from a wide variety of material types is also an advantage. We utilize machining centers, as well as composite lathes and engraving machines. In addition to 3D processing and multi-surface processing, we also accommodate gears, polished transparent processed products, and large shape processing. Our company has facilities at five locations in Japan and overseas factories, and we are continuously working to provide ultra-fast responses and low-cost solutions.

• Prototype Services

Zen Corporation not only works with resin but also performs metal cutting, and is capable of 5-axis machining that requires multi-surface processing. We also handle machining of ADC and ZDC cast materials as well as magnesium. We manufacture precision mechanical parts and jig components. Similar to resin cutting, we can also produce rod-shaped parts through lathe machining. Additionally, we can take care of various plating, heat treatment, and polishing, so you can leave everything to us.

• Prototype Services

Microfabrication utilizes advanced processing techniques such as high-precision cutting, hole machining, wire cutting, and electrical discharge machining to manufacture metal micro-components according to your specifications. With years of cultivated expertise, we can accommodate various shapes, including ultra-thin profiles and tiny hole shapes, down to approximately 0.05mm. Additionally, we offer one-stop solutions for surface treatment and plating of the manufactured parts. The produced components are so small that their shapes cannot be distinguished by the naked eye, but we ensure quality by measuring them using a measuring microscope. We have extensive experience in manufacturing precision parts for medical applications and precise mechanical components, so please feel free to contact us if you have any needs for micro or precision parts.

• Contract manufacturing

At Zen, we are capable of producing casting parts with industry-leading precision through our long-established mold-making methods. We also excel in creating transparent parts, such as clear castings and colored transparent castings. Using the original product as a master, we create a mold with silicone, then pour materials like urethane resin into the completed silicone mold to produce replicas of the original. From a single silicone mold, it is possible to create approximately 15 to 20 replicas. Therefore, during the prototyping phase, where a large number of units are required, significant cost reductions can be achieved.

• Prototype Services

We apply paint to mechanical parts, mock-ups used in exhibitions and presentations, mass-produced products, etc. We also offer a wide range of surface finishes, including pearl coating and textured coating. It is possible to print your company's logo or text in specified areas using silk screen printing or pad printing, which can print on curved surfaces. We can also perform laser etching on the painted areas to reflect text or logos. In addition to prototypes manufactured by our company, we also accept existing parts and mass-produced products for "painting only" services.

• Prototype Services

Injection molding involves pouring melted resin (plastic) into a mold to create parts that conform to the shape of the mold. At Zen, we manufacture simple molds and perform injection molding to accommodate medium-lot production of resin parts and small-scale mass production. These simple molds (prototype molds) are made from easily machinable materials like aluminum, allowing for quick production of molds. Additionally, by making the molds cassette-style, we can standardize the mold base, which allows us to reduce the size of the molds themselves, thereby lowering costs and shortening delivery times compared to mass production molds. Since the molds are made from materials like aluminum or ZAS, their lifespan is shorter compared to mass production molds, with shot counts around 10,000 shots (depending on the shape). "Do you need a relatively large number of plastic parts!?" "The cost of mass production molds is too high. Can it be cheaper!?" "Is verification with the same molding material as mass production necessary!?" This is recommended for such situations. We can procure the desired materials or accommodate those provided by the customer.

• Prototype Services

A mock-up refers to a model that only represents the appearance of a product without implementing its internal mechanisms. It is used in the prototype stage of product development to confirm the shape/design of the appearance, as well as for advertising and promotional purposes to explain the product and verify its appearance at exhibitions. At Zen, we cater to both design models for product development and mock-ups for display, creating models (mock-ups) that closely resemble the actual product to meet various needs. The mock-ups we produce can not only confirm the shape and design but can also be equipped with electrical components. Utilizing Zen's processing, finishing, and decoration techniques, we ensure that you can verify the texture, appearance, and usability at a quality level equivalent to actual mass-produced products.

• Prototype Services

We have numerous achievements in seal production for prototypes and small lots. Basically, we use a die called a "biku-gata" for cutting. We can accommodate bending processing of films and half-cut seals. Additionally, we also support three-dimensional shapes through embossing using PC materials. We respond to various embossing processes, such as creating uneven surfaces on caps and film surfaces after applying silk printing and other treatments.

• Prototype Services

Precision sheet metal processing involves using bending machines, laser processing machines, and other equipment to perform bending, hole processing, drawing, and welding on flat metal sheets, creating prototype mechanical components, enclosures, and exterior parts. We also accommodate prototypes for springs, coil springs, and more. Feel free to entrust us with various types of plating as well. We can process using only 3D data, reducing the time needed to create drawings and layouts. Additionally, we can handle prototypes using materials supplied by customers.

• Prototype Services

Since we directly create three-dimensional shapes based on 3D CAD data, we can easily form shapes that are difficult to process with cutting.

• Prototype Services
• 3D Printer