吉田テクノワークス Product Lineup

Our glass insert in-mold (GIM) method combined with Korean-made reinforced plastic plates achieves the best of both worlds. *This is a new method currently under development. It will be an integrated product of molded bezels and display window plastic plates for various display device cover applications. There are no steps or gaps between the bezel and the plastic plate, and by adopting a narrow frame design, it ensures a seamless touch experience for users without any snags. The bezel can be finished with a matte design using in-mold transfer decoration, reducing reflection and preventing glare. Additionally, the back of the bezel can be designed with a fitting structure, enhancing assembly compatibility and reworkability with housing components. In addition to the same features as GIM, replacing glass with reinforced plastic plates is expected to provide benefits such as weight reduction, lower costs, and reduced risk of breakage.

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Reinforced glass is often used for protective covers on LCD displays of mobile devices, automotive, and industrial equipment. While glass is hard and offers high touch sensor sensitivity and no distortion, it is also heavy, carries a risk of breakage, and has high costs. This resin plate made in Korea is a single-layer sheet with no distortion and transparency equivalent to glass, and it has a pencil hardness of up to 7H when combined with a hard coat. Due to the extrusion method, it can be produced in thicknesses of 0.5mm or more, and large-format production and bending processing are also easy. Surface treatments include hard coating as well as AR (anti-reflective) and AFP (anti-fingerprint) coatings. It complies with specifications from Korean automotive manufacturers.

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There are several methods for film decoration on 3D molded products, such as TOM, in-mold transfer, and VSS (Vacuum Simultaneous Stretching), but the optimal method varies depending on the part shape, material, and required quality. The VSS method, which Yoshida Techno Works specializes in, involves simultaneously stretching a thermoplastic film into a three-dimensional shape through vacuum, pressure, and heating, adhering and bonding it to the surface of the molded product. It has advantages over the TOM method for deep-drawn shapes and for decoration on non-thermoplastic substrates such as CFRP and metal. This article will explain the principles of the VSS method, its benefits, a comparison with the TOM method, and points for material selection.

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• Contract manufacturing

There is a growing demand for spot sound that delivers audio explanations and sound effects of each exhibit "only to the person in front of that exhibit" in museums, art galleries, showrooms, and exhibition booths. Conventional directional speakers have been large, high-cost, and difficult to install, but Yoshida Techno Works' compact directional speaker module is easy to retrofit onto existing display panels and digital signage due to its slim panel shape. By arranging multiple modules in a "sound partition" configuration, it prevents sound interference between adjacent exhibition areas. It is also compatible with multiple languages, touch panel interaction, and sensor interaction.

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• Other PCs and OA equipment

If manufacturability is not considered during the design phase of product development, issues such as "shapes that cannot be molded," "structures prone to decoration defects," and "costs exceeding expectations" may arise during the transition from prototype to mass production, leading to significant design changes and development delays. At Yoshida Techno Works, DFM (Design for Manufacturability) engineers participate from the customer's design phase to support design optimization from the perspectives of moldability, decoration transfer accuracy, mold costs, mass production costs, and quality risks. Through simulations using flow analysis and cooling analysis, we predict and address molding issues before mold fabrication.

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• Contract manufacturing

In new product development, when orders are placed with separate companies for mold manufacturers, molding manufacturers, decoration manufacturers, inspection outsourcing, and assembly manufacturers, it leads to losses in information transmission, unclear responsibility for quality issues between processes, and cumulative risks of delivery delays. Yoshida Techno Works provides a "one-stop service" that consistently handles everything in-house, from mold design and manufacturing to injection molding, in-mold decoration, post-processing, quality inspection, and packaging and shipping. By consolidating points of contact from the concept stage through design consultation and DFM support to mass production transition, we can expect reductions in development man-hours and coordination costs.

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• Contract manufacturing

CFRP and GFRP parts used in road bikes, sports helmets, and outdoor equipment are lightweight and high-strength, but the options for surface decoration have been limited, mostly relying on painting and sticker application. With Yoshida Technoworks' VSS method, high-precision decoration on complex curved surfaces of CFRP and GFRP can be achieved by vacuum-pressing and integrating printed films onto the 3D shapes. This allows for the addition of designs such as carbon patterns, graphic designs, and gradients, contributing to reduced environmental impact by eliminating the need for painting. Please consult us for small-scale prototypes.

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• Contract manufacturing

In industrial equipment such as FA machines, machine tools, measuring instruments, and control panels, the characters and symbols on the operation panels are applied using label seals or printing. Over time, peeling, wear, and dirt accumulation can lead to increased maintenance costs and the risk of incorrect operations. Yoshida Technoworks' in-mold transfer decoration method encapsulates designs such as characters, symbols, and gradients within the resin, resulting in label-free panels that do not deteriorate even when exposed to friction, chemicals, or UV radiation. We support the prototyping and mass production of display panels for industrial equipment that combine chemical resistance and wear resistance.

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• Contract manufacturing

In the interiors of electric vehicles such as EVs, PHVs, and FCVs, there is a demand for parts that simultaneously meet the requirements of a metallic design, radio wave permeability, lightweight interior components, and a luxurious surface design. Using Yoshida Technoworks' discontinuous vapor deposition film in in-mold forming technology, it is possible to mold decorative panels that have a metallic luster while allowing radio waves to pass through. Furthermore, the double in-mold method enables the integrated molding of a metallic decorative layer and a protective coat layer, eliminating the need for subsequent painting or coating processes. The molding based on lightweight PC resin is expected to achieve significant weight reduction compared to existing metal components.

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• Contract manufacturing

The in-mold decoration method is broadly divided into two types: "in-mold labeling (integrated molding with a label that leaves a film on the molded product)" and "in-mold transfer decoration (integrated molding that transfers only the thin film transfer layer to the resin)." If the characteristics and suitability of each are not correctly understood, there is a risk of quality issues or cost overruns after transitioning to mass production. In-mold labeling is a method that leaves a thick film on the molded product, excelling in wear resistance and decoration precision. In-mold transfer decoration is a method that transfers only the thin film transfer layer to the resin, resulting in no film residue and superior surface quality and optical properties. Yoshida Techno Works handles both methods in-house and proposes the optimal method based on part shape, production quantity, quality requirements, and cost targets.

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• Contract manufacturing

There is a growing demand for high-design decorative finishes such as real wood, stone, and carbon looks in automotive interiors and lifestyle products. Traditional painting and vapor deposition methods have faced challenges with durability and environmental impact, but in-mold transfer decoration allows for the simultaneous transfer of finely printed wood and stone pattern films during resin molding, enabling mass production of decorative items that combine weather resistance, abrasion resistance, and uniformity. Yoshida Techno Works provides comprehensive support from film grade selection to mold design and optimization of molding conditions, offering high-design and highly stable mass-produced in-mold decorative items.

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• Contract manufacturing

In electronic devices, medical equipment, and automotive components, when integrating glass panels with metal frames, traditional methods required subsequent processes such as adhesion, fitting, and screw fastening, leading to increased component count, reduced waterproof reliability, and rising costs. Yoshida Techno Works' glass-metal composite insert molding technology simultaneously inserts glass and metal terminals or frames into the same mold and encapsulates them with resin. We implement measures against residual stress caused by the difference in linear expansion coefficients of glass, metal, and resin from the mold design stage, providing stable quality integrated molded products. Please also consult us regarding waterproof performance and our comprehensive air leak inspection system.

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• Contract manufacturing

In sheet metal insert molding, if the front and back of the sheet metal are mistakenly set during molding, it can lead to serious issues such as functional defects, appearance defects, and mold damage. A system that relies on manual setup and visual confirmation cannot completely prevent human errors during long hours of mass production. At Yoshida Techno Works, we have developed an in-house dedicated robot for the automatic transport of sheet metal to molds for mass production of exterior panels for electronic cigarettes, establishing a method that incorporates front and back detection cameras along the transport route. Sheet metal that is judged as NG (not good) by the camera's front and back determination is automatically eliminated, ensuring that only correctly oriented sheet metal is inserted into the mold. By integrating automatic transport and front/back detection, we achieve zero misinsertion while maintaining the pace of mass production. We also accommodate customization of robots and jigs according to the shape and size of the sheet metal.

• Contract manufacturing

In glass insert molding (GIM), even within standard values, variations in the thickness of the glass material can affect compatibility with the mold, leading to uneven molding pressure, glass breakage, and appearance defects. Yoshida Technoworks has established a method for mass production of GIM for Kyocera's JA83, where the thickness of the glass is classified in increments of 0.02mm, and rank management is implemented through weight selection. Furthermore, by associating the glass rank with the molding conditions for each mold number, variations within the same material are absorbed by the molding conditions, ensuring stable mass production quality. This method is particularly effective in improving yield for GIM products that use thin glass (1mm or less).

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• Contract manufacturing

In vehicle-mounted CID (Center Information Display), it is required that the appearance of the molded resin frame surrounding the GIM glass matches the appearance of the housing (metal and paint). However, tuning the molded product to match the matte texture of aluminum die-cast or painted housings is quite challenging, and if there are discrepancies in appearance, a high-quality design cannot be achieved. Yoshida Techno Works has finely adjusted the gloss, texture, and color tone of IMD foil decoration, successfully achieving the tuning to match the matte appearance of the CID housing with the appearance of the molded frame in the DNP F40GIM (vehicle prototype). Through the combined optimization of film grade, molding conditions, and mold texture, stable appearance matching is realized even in mass production.

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• Contract manufacturing

In glass insert molding (GIM), if the insertion position of the glass into the mold varies, it can lead to various molding troubles such as uneven resin filling, glass misalignment, sealing defects, and appearance issues. Yoshida Techno Works has developed and adopted a unique insertion method that incorporates a centering mechanism on the glass insert platform, allowing for precise positioning using guide pins when inserting the glass into the mold. This method eliminates variations in position during manual glass insertion and ensures stable insertion accuracy across all mass-produced units. We have established this method in the mass production of DL35 (GIM products) for Sharp, significantly reducing molding defects caused by glass positioning issues.

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• Contract manufacturing

In smartphone and automotive display panels, an anti-fingerprint (AFP) function that minimizes the visibility of fingerprints is required; however, coating processes after molding can lead to increased steps and risks of poor adhesion. Yoshida Technoworks has established a method to impart AFP functionality simultaneously with molding by incorporating water and oil repellent components into the surface film (surface foil) in the double in-mold process. Since the coating process is unnecessary, this achieves simplification of subsequent processes and cost reduction, while the surface foil is integrated with the resin, providing excellent adhesion and abrasion resistance. There is a track record of mass production applied to BC7/VG4 cover lenses, and the formulation of the water and oil repellent components in the surface foil can be customized according to your requirements.

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• Contract manufacturing

Large, thin-walled cover lenses and resin panels are prone to warping and distortion during the cooling process after molding, which can lead to assembly defects and appearance issues. Traditional sampling three-dimensional measurements made it difficult to guarantee the entire production. Yoshida Techno Works has developed a dedicated measurement fixture with multiple non-contact displacement sensors to quantitatively acquire and manage coordinate data (warping amount) for all molded products. The measurement data is recorded and stored on a lot basis and is also used for feedback to optimize molding conditions. This initiative has significantly reduced the risk of defective products with shape issues leaking out and has eradicated assembly defects in subsequent processes.

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• Contract manufacturing

In cover lenses and automotive exterior panels, light stability that prevents yellowing and appearance deterioration due to long-term UV exposure is required. Yoshida Techno Works has established a method to incorporate UV-absorbing components into the surface film (surface foil) in the double in-mold process, granting light stability functionality simultaneously with molding. Since post-molding painting and coating processes are unnecessary, we achieve process reduction and cost reduction while passing light stability tests. In addition to our application results for BC7/VG4 cover lenses for Fujitsu Plastics/Rhythm Shoei, we also have a track record of proposing and passing tests for weather-resistant foils for automotive parts (K0F) for Honda Motor Co. The formulation of UV-absorbing components and film selection can be customized according to product requirements and testing standards.

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• Contract manufacturing

In the mass production of optical products such as cover lenses, the cutting labor time for post-processing can become a bottleneck in the manufacturing lead time. Yoshida Techno Works has introduced a high-speed cutting machine (Joker) dedicated to resin products, achieving a quick startup. Compared to conventional general-purpose machining equipment, it significantly improves cutting speed and establishes a consistent production system with the molding line. This allows for the reduction of processing labor time and the rationalization of manufacturing lead time, thereby establishing a stable supply system for mass-produced products. We have also accumulated in-house know-how for setting up tools and conditions to maintain cutting precision while keeping up with mass production pace, supporting a quick transition to mass production during the launch of new models.

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• Contract manufacturing

Are you struggling with the adhesive strength of glass falling below standard values during the bonding process after GIM (Glass In-Mold) molding, affecting the stability of mass production quality? Applying adhesive to the side (cross-section) of the glass can lead to variability in uniformity due to the complex shape, often resulting in insufficient bonding area, which is a common cause of inadequate strength. Our company has introduced a dedicated robot capable of uniformly applying adhesive around the entire circumference of the glass side, precisely controlling the amount, position, and speed of application to stabilize the bonding area and quality. As a result, we have successfully resolved adhesive strength issues for GIM waterproof products at the mass production quality level. We look forward to consultations from manufacturers seeking to improve the waterproof performance and adhesive reliability of glass-integrated molded products.

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• Contract manufacturing

In precision machining products, there is a strict tolerance requirement of ±0.05mm, and there is a risk of overlooking defects in sampling inspections, making it challenging to establish a system for 100% assurance. Using general equipment and standard inspection flows is not realistic for managing high-precision tolerances, and there are many cases where we cannot meet the quality demands of major manufacturers. Our company has established a 100% measurement flow for ±0.05mm tolerance products through continuous improvement of dedicated jigs and in-house design and manufacturing of measuring instruments specialized for 100% assurance. By producing measuring instruments in-house, we keep costs down while achieving high measurement reproducibility unique to dedicated designs. We support 100% quality assurance for precision parts, optical components, and high-precision electronic components, meeting the strict quality standards of major manufacturers.

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• Contract manufacturing

Are you facing issues with frequent glass breakage and instability in mass production using 3D curved glass in insert molding? Since the curvature of curved glass slightly differs for each product, the mismatch with the mold curvature creates localized overloading, leading to breakage. Our company has established a unique management method that measures the curvature of curved glass for all units, databases the data, and quantitatively analyzes the differences from the mold curvature. By directly feeding back the measurement data into mold adjustments, we significantly reduce the risk of breakage and achieve stable mass production. We also have a proven track record in solving breakage issues for curved glass used in high-end smartphones, making us ideal for manufacturers aiming for stable production of high-precision 3D molded products such as curved displays and wearable components.

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• Contract manufacturing

In glass insert molding, are you struggling with issues where glass or molds break due to individual differences (thickness variations) even within specifications? Even with standardized insert glass, minute dimensional differences are unavoidable, and molding them as is can lead to excessive pressing force, increasing the risk of breakage. Our company has designed and implemented a unique mechanism that automatically adjusts the interior of the mold in response to the individual thickness variations of the insert components. By consistently maintaining appropriate pressing strength, we prevent breakage of both glass and molds, significantly improving yield and equipment utilization rates. This is the ideal solution for manufacturers facing challenges in the stable production of high-quality glass insert molded products, such as those used in smartphones, tablets, and automotive parts.

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• Contract manufacturing

Are you struggling to achieve both a reduction in polarization distortion (retardation) and shape accuracy in the manufacturing of resin panels for automotive and industrial displays? In general annealing processes, distortion is often removed at the cost of panel shape deformation, making it challenging to meet both precise dimensional requirements and quality standards simultaneously. Our company has uniquely established STAR treatment conditions that effectively reduce retardation while minimizing shape deformation. Additionally, we design and manufacture specialized tools to properly hold the panels during processing. This combination allows us to achieve mass production that meets the quality standards for precision panels. We look forward to consulting with manufacturers facing quality challenges in display panels for automotive, industrial, and medical devices.

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• Contract manufacturing

As manufacturers struggle with the quality issue of increased residual stress during the molding process, which leads to rainbow-colored distortions (retardation) visible through polarized sunglasses as the size of transparent panels increases, our uniquely developed "STAR treatment" is a technology that fundamentally suppresses residual stress by comprehensively controlling multiple molding parameters such as gate temperature, holding pressure, and injection conditions. Since it does not require changes in materials or modifications to molds, it can resolve issues while utilizing existing equipment and design assets. This technology achieves stable quality at mass production levels for applications with stringent optical properties, such as automotive displays, smartphones, and PC resin panels for tablets. We hope that manufacturers aiming to reduce non-conforming lots in polarized inspections, curb customer complaints, and improve yield will find this technology beneficial.

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• Contract manufacturing

Conventional speakers diffuse sound over a wide area, making it difficult to deliver sound only to people in specific locations within exhibition facilities and commercial spaces. By adopting super-directional speaker (parametric speaker) technology, we have built a system that delivers sound exclusively to specific areas or individuals. Through acoustic characteristic evaluation and adjustments, we have achieved selective sound transmission to designated areas. This contributes to immersive audio experiences, such as audio guides in front of exhibits in museums and exhibition facilities, promotional sound in stores, and individual audio in hospital waiting rooms.

• Sound Parts

The collaboration project for the heating device required a small lot, diverse variety, and short delivery times. Due to frequent user complaints from another manufacturer, there was a demand for both quality and supply stability. Leveraging the strength of mass-producing the base product, we combined inkjet printing and painting processes on the base to accommodate a variety of products with short lead times. We eliminated the user complaints that were prevalent with another manufacturer and established a supply chain capable of short delivery times. By designing processes to minimize the lead time for switching product varieties, we achieved stable supply of exterior parts necessary for small-lot production of collaboration and limited edition products.

• Processing Contract

There are only a limited number of suppliers capable of designing and manufacturing automated lines optimized for customer-specific molding processes, leading to difficulties in procurement. From the initial estimation stage, we present conceptual drawings and ladder diagrams (which is rare among other companies) and make proposals from multiple angles to meet customer requests. After careful negotiations by a specialized technical team, we design and develop automated assembly, processing, and inspection lines that work in conjunction with molding machines from scratch. With an unparalleled automated machine sales service in the molding industry, we gain customer trust through conceptual proposals from the estimation stage.

• Assembly robot

The realization of the click sensation for electronic cigarette components, which was consulted by a major tobacco brand, was considered impossible by other companies (in China). Achieving the click sensation required precise thickness adjustments, but relying solely on injection molding resulted in dimensional variations that made it difficult. We adjusted the thickness after molding using a special cutting machine for secondary processing to achieve the click sensation. To address the variations in processing thickness caused by dimensional variations in molding, we designed and manufactured dedicated jigs in-house to resolve the issue. By providing a consistent response from molding to secondary processing, we enable mass production of electronic device components with a precise click mechanism that cannot be achieved by other companies.

• Contract manufacturing

The complex-shaped components of major cosmetic brands were projects that multiple companies, both domestic and international, had declined, stating that "the structure is too complicated." It was also difficult to realize using the material (elastomer), and it was necessary to meet the high design requirements unique to the cosmetics industry. By applying the mold structure know-how cultivated in high-level industries such as home appliances, automobiles, and communication equipment, we proposed and constructed a mold structure that could be mass-produced. We successfully achieved the mass production of products for major cosmetic brands while fully realizing the designers' designs. Even for difficult-shaped components that other companies have declined, we positively consider and propose solutions.

• Contract manufacturing

There are few decoration variations for materials other than resin (metal, glass, CFRP/GFRP), and traditional TOM molding has issues with the substrate becoming too thick and concerns about high transfer temperatures affecting the fabric (risk of deformation). We established the VSS method, which applies in-mold technology to transfer only the ink layer. By combining a dedicated stretchable transfer foil with our unique overheating steam heating method, we achieved transfer at low temperatures and in a short time. We have also resolved the thickness issues of TOM molding, enabling thinner designs. We have a track record of final adjustments for commercialization in global brand laptops and will mass-produce high-quality 3D decorations for metal, carbon, and glass.

• Processing Contract

Even if the functions of anti-reflective (AR), anti-glare (AG), and anti-fingerprint (AFP) can be achieved using the IML method, it was structurally impossible to balance them with a high-design aesthetic that takes advantage of the depth of transparent resin. Additionally, there was a problem with the printing layer affecting the color of the LCD backlight in the HIDDEN decoration on the back side. We established a hybrid molding method that inserts an optical function sheet (AR/AG/AFP compatible IML sheet) on the surface and applies in-mold decoration on the back side. By adopting the special printing technology of a major printing manufacturer, we achieved HIDDEN decoration that does not affect the color development of the LCD. We simultaneously realize the functionality of anti-reflective, anti-glare, and anti-fingerprint with a high-design aesthetic that has depth in a single panel.

• Contract manufacturing

In the molding of magnetic inserts for heating devices, the risk of incorrect insertion of the magnets' front and back sides and polarity, as well as the magnetic influence on the molds, had been a cause of mass production troubles. We developed an in-house automatic transport robot that utilizes the polarity of the magnets to prevent incorrect insertion, and we adopted special mold steel that is not affected by magnetism for the product components (cavity cores). We have achieved the elimination of mass production troubles related to magnetic inserts and zero defects from incorrect insertion. By in-house development of the automatic transport robot, we can flexibly build an automated line optimized for the customer's specific molding process.

• Contract manufacturing

In the vehicle-mounted testing (heat cycle testing), a problem occurred where the glass detached from the molded resin frame, making it difficult to meet the quality standards for vehicle-mounted glass insert products. Additionally, it was necessary to match the matte appearance of the vehicle-mounted housing with that of the molded resin frame. We selected a filler-containing resin that minimizes molding shrinkage and confirmed its durability in heat cycle testing. We also conducted tuning to match the matte appearance of the CID housing with the in-mold foil decorative appearance of the molded resin frame, achieving application to vehicle-mounted CID cover panels and vehicle-mounted display frames.

• Contract manufacturing

In glass insert molding (GIM) products, while waterproof guarantees are required, it has been difficult to establish a system for detecting and guaranteeing minute leaks at the interface between glass and resin for all products. We introduced an air leak testing machine, set threshold values for each product, and conducted 100% inspection. For products that failed the tests, we established a rework system to apply impregnation adhesive through additional processing. Furthermore, we improved structural waterproofing by enhancing glass positioning accuracy with centering on the insert glass support and guide pins. We have established a quality assurance system for all GIM waterproof products, which supports waterproof smartphone cover panels and more.

• Contract manufacturing

In the glass bonding to the resin frame, it was not possible to achieve zero "gaps," and due to the dimensional variations in the glass, a seamless appearance could not be realized in the subsequent bonding process. We established a unique method that aligns the 3D shape of the glass with the shape of the mold for insert molding, simultaneously implementing metal inserts and in-mold decoration during the molding process. This method achieves the insertion of three different materials: glass, metal, and in-mold (decoration) in the same molding process. We developed a unique mold mechanism that absorbs the individual differences (dimensional variations) of the glass, realizing a seamless sealing structure without the need for tape and enabling larger screen sizes. There is a proven track record of being adopted in ultra-high-end premium smartphones.

• Contract manufacturing

The issue of decreased antenna sensitivity in smartphones, Bluetooth devices, and in-vehicle devices when applying metallic decorative finishes was due to traditional plating and aluminum vapor deposition shielding the radio waves. By depositing tin (tin) in a discontinuous island-like manner at the nano level, we developed a unique deposition in-mold foil that maintains an electrically insulating state while visually emitting a uniform metallic luster. We established a new method that achieves a metallic appearance while allowing radio waves to pass through. This will be adopted in smartphone casings, Bluetooth-equipped devices, and automotive components, providing a high-transparency metallic exterior that does not interfere with radio waves in mass production.

• Contract manufacturing

In cases where multiple decorative in-mold processes are performed on deep-drawn shapes, ensuring alignment accuracy between each cavity is technically challenging, and other companies have deemed such projects unfeasible. By independently developing a specialized multi-cavity mold structure and precisely designing the alignment mechanism for each cavity, we have successfully achieved mass production of deep-drawn multi-cavity in-mold products. We proactively tackle high-difficulty shapes and structures that other companies have declined, proposing and constructing mold structures that are capable of mass production. We cater to the manufacturing of high-design exterior components for beauty and healthcare devices, as well as smartphone-related products.

• Contract manufacturing

As part of the product's carbon neutrality efforts, the use of recycled resin (PCR-PC) is required; however, there were concerns about its impact on the flowability and transfer quality specific to in-mold forming, making it difficult to balance environmental considerations with mass production quality. We explored and selected suppliers of PCR-PC resin suitable for in-mold forming and optimized the molding conditions (temperature, pressure, filling speed). After evaluating the materials (flowability, transfer quality, appearance quality) and confirming compatibility with the foil, we established a manufacturing system that simultaneously achieves mass procurement of environmentally friendly products and maintains in-mold quality with PCR-PC resin. We support decorative molding that meets sustainability requirements.

• Contract manufacturing

In the exterior panel of heating devices, it was technically difficult to mass-produce designs that convey a sense of luxury and depth using only single-sided in-mold. We established a unique method that incorporates three-dimensional UV patterns into the in-mold transfer layer, achieving three-dimensional decoration simultaneously with injection molding. Despite being single-sided in-mold, we successfully mass-produced designs that convey a sense of depth and luxury, which have been adopted by major heating device manufacturers. As a technology that opens up new possibilities for in-mold decoration, it can also be applied to smartphone back covers and appliance control panels.

• Contract manufacturing

Conventional light guide plates typically consist of a three-layer structure made up of two vapor-deposited plates (front and back) and a transparent plate, which has made the high number of components a bottleneck for thinness and space-saving. Additionally, the method of combining plate materials made it difficult to accommodate three-dimensional shapes, greatly restricting design flexibility. By applying double in-mold forming to the production of light guide plates, both sides of the vapor-deposited foil are transferred within the mold simultaneously during injection molding. This consolidates the conventional three-layer structure into a single molded product, achieving significant thinness and a reduction in the number of components. Leveraging the design freedom unique to injection-molded products, it can accommodate curved and complex shapes that were impossible with traditional methods. This contributes to the high design quality and space-saving of automotive ambient lighting and LED panels for home appliances.

• Contract manufacturing

It was difficult to simultaneously apply anti-fingerprint (AFP), anti-glare (AG), anti-reflective (AR) coatings, and a sense of depth design to cover lenses for car navigation systems using conventional methods. Additionally, there was a demand to comply with outgassing regulations for automotive environments and to ensure durability in light resistance tests. We adopted a functional film that incorporates water-repellent and oil-repellent (AFP) components and UV-absorbing components into a double in-mold surface foil, achieving a sense of depth through graphic decoration on the back side. We established a quality assurance system by introducing non-contact displacement gauges for all products, allowing for quantitative management of 3D shapes (warpage) at multiple measurement points. We have simultaneously achieved passing light resistance tests, applying anti-fingerprint coatings, and conducting quantitative management of all products.

• Contract manufacturing

In the home appliance industry, the contamination of floating particles during the AR processing stage has become a challenge that negatively affects yield rates. Improving yield is a crucial theme for operation panels, which significantly influence product quality. Additionally, there is a demand to achieve a design with transparency alongside surface treatment. In response to these challenges, our double in-mold method realizes dual-side decoration in a single injection molding process, contributing to yield improvement. 【Usage Scenarios】 * Operation panels for home appliances * Display panels requiring AR processing * Products that aim to balance design and functionality 【Benefits of Implementation】 * Improvement in yield during the AR processing stage * Enhancement of design quality * Streamlining of the manufacturing process

• Contract manufacturing

We would like to introduce a case where we designed and developed an automatic assembly, processing, and inspection line from scratch to optimize production equipment. In building a dedicated line for stable mass production of molded products, we faced the challenge that general equipment manufacturers lacked the know-how for molding. In response, we presented "conceptual diagrams and ladder diagrams" from the planning stage and designed and developed the automatic assembly, processing, and inspection line itself, which is linked to the molding machine, from scratch. [Case Overview] ■ Challenges Faced: General equipment manufacturers lack molding know-how in building dedicated lines. ■ Solution: Designed and developed an automatic assembly, processing, and inspection line linked to the molding machine from scratch. ■ Value Created: Established a consistent quality assurance system from molding to assembly and developed a unique support system that also accommodates the external sales of standalone automatic machines. *For more details, please download the PDF or feel free to contact us.

• Other assembly machines
• Other inspection equipment and devices
• Other factory equipment