吉田テクノワークス Product Lineup

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

We would like to introduce a case where we successfully mass-produced a beauty brush with a complex three-dimensional shape that was deemed impossible to mold. This product features a special three-dimensional skeleton structure that manufacturers both domestically and internationally had given up on, stating that "the mold structure is too complex for mass production." By applying the advanced mold design know-how cultivated through high-difficulty in-mold processes to general molding, we constructed a special mold structure that clears complex undercuts. We succeeded in mass-producing products for major brands. 【Case Overview】 ■ Challenges Faced: The mold structure for the beauty brush with a special three-dimensional skeleton structure was too complex for mass production. ■ Solution: We applied advanced mold design know-how to general molding and constructed a special mold structure that clears complex undercuts. ■ Value Created: Successfully mass-produced products for major brands without compromising the designer's design. *For more details, please download the PDF or feel free to contact us.

• Processing Contract

We would like to introduce a case study that addresses the challenges of narrow bezels and waterproofing in smart devices through glass inserts and in-mold technology. In this case, there was a challenge that narrow bezels and waterproofing could not be guaranteed with conventional tape adhesion. Therefore, we developed a special mold mechanism and adhesive technology that completely integrates fragile glass and resin within the mold. This achieved a seamless, fully sealed structure without the need for tape, as well as larger screen sizes. [Case Overview] ■ Challenges Faced: Narrow bezels and waterproofing in smart devices could not be guaranteed with conventional tape adhesion. ■ Solution: Developed a special mold mechanism and adhesive technology that completely integrates glass and resin within the mold. ■ Value Created: Achieved a seamless, fully sealed structure without the need for tape and larger screen sizes. *For more details, please download the PDF or feel free to contact us.

• Processing Contract

We would like to introduce a case study of tin vapor deposition in-mold, which achieves both radio communication and a metallic appearance. In this case, there was a dilemma of wanting to apply a luxurious metallic decoration, but traditional aluminum vapor deposition would block the device's radio waves. Therefore, we established a new decoration method that utilizes the characteristics of "discontinuous vapor deposition films" that allow radio waves to pass through. This has resulted in a highly transparent metallic exterior that does not interfere with 5G communication or wireless charging. 【Case Overview】 ■ Challenges Faced: Traditional aluminum vapor deposition blocks the device's radio waves ■ Solution: A new decoration method that leverages the characteristics of "discontinuous vapor deposition films" that allow radio waves to pass through ■ Value Created: Achieved a highly transparent metallic exterior for communication devices that does not hinder 5G communication or wireless charging *For more details, please download the PDF or feel free to contact us.

• Processing Contract

We will introduce a case that resolved the polarization distortion (retardation) associated with the enlargement of transparent panels in the automotive industry. The resolution of the inevitable polarization distortion resulting from the enlargement of transparent panels posed a challenging requirement that our company had no prior expertise in. In response, we fundamentally re-evaluated our existing know-how and established and implemented new solutions such as retardation elimination technology (STAR treatment) to overcome this challenge. 【Case Overview】 ■ Challenge Faced: Elimination of polarization distortion (retardation) due to the enlargement of transparent panels ■ Solution: Newly established and implemented retardation elimination technology (STAR treatment) ■ Value Created: Demonstrated problem-solving ability by creating new methods and treatments to achieve customer objectives *For more details, please download the PDF or feel free to contact us.

• Other FPD related

We would like to introduce a case where we solved the challenges of enhancing the clarity of LCD screens and achieving dual-sided decoration using our uniquely developed "Double In-Mold Method (W-IMD)." Traditionally, post-processing to enhance the clarity of LCD screens had low yield rates, becoming a barrier to mass production. Additionally, there were conflicting demands for advanced dual-sided decoration in some products. Our company enabled simultaneous decoration on both sides by adopting a reverse-thinking approach of drilling holes in the film and pouring in resin, thus achieving mass production of high-value-added products. 【Case Overview】 ■ Challenges Faced: Post-processing to enhance the clarity of LCD screens had low yield rates, becoming a barrier to mass production. ■ Solution: Independently developed the "Double In-Mold Method (W-IMD)" to enable simultaneous decoration on both sides. ■ Value Created: Achieved mass production of high-value-added products, including camera-equipped mobile phones. *For more details, please download the PDF or feel free to contact us.

• LCD display

A film (in-mold foil) with a pre-printed design is sandwiched between molds, and resin is poured in. The heat and pressure of injection molding simultaneously transfer the design during the molding process. Unlike methods that apply decoration after molding, this molding technique efficiently achieves a more beautiful exterior design, developed in 1973 by Yoshida Technoworks, pioneering the world. Building on this in-mold molding, we have evolved our technology to include double in-mold, which decorates both the surface and the back of the molded product simultaneously. We also have tin vapor-deposited in-mold that expresses a beautiful metallic feel without interfering with radio waves, indium in-mold, and two-color in-mold that utilizes the texture of plastic and vibrant colors to enable deep decoration. Additionally, we have developed various in-mold molding techniques, such as glass insert in-mold, which enhances adhesion and waterproofing by integrally molding glass and resin. For the development story, please check the URL below! *For more details, please refer to the PDF or feel free to contact us.

• Touch Panel
• LCD display
• Interior parts

To all those involved in medical devices, Do you have these challenges? □ Want to shut out viruses and bacteria from touch panels that are touched by fingers □ Want to add antibacterial properties to medical device monitors □ Looking for a hygienic touch panel that is resistant to dirt Introducing challenges and solutions! [Challenge] When cutting large quantities of glass plates, slight dimensional variations occur, which can create small gaps and steps when fitted into plastic or metal bezels. [Solution] By using glass insert in-mold forming, we can eliminate the gaps and steps between the glass and the bezel. This will remove gaps and steps where bacteria can easily enter, resulting in hygienic and safe monitors and touch panels. *For more details, please refer to the PDF or feel free to contact us.

• Touch Panel
• LCD display
• Interior parts

【Customer Development Needs】 We were requested to insert metal parts to improve the assembly compatibility with the casing body in LCD panels for mobile devices. 【More Specific Requirements】 1. We would like you to insert nuts for screws during the molding process to securely hold them on the back of the in-mold transfer molded product. 2. Since the resin frame of the Glass Insert Molding (GIM) is thin and cannot achieve a fitting structure, we want to insert sheet metal simultaneously to enhance assembly compatibility with the casing. 【Our Proposal】 1. We developed an automatic feeder device that identifies the front and back of the nuts for insertion, and in conjunction with the in-mold transfer method, we proposed an LCD panel with decorative features and back-mounted nuts. 2. We proposed a GIM method with sheet metal inserts, partially hollowing out SUS sheet metal to allow the molded resin to fill in and securely hold the narrow frame. 【Customer Evaluation】 1. Thanks to the strong nuts inserted into the decorative LCD window, we received positive feedback from various mobile device manufacturers regarding improved assembly compatibility with the casing body. 2. We successfully addressed the need to balance the narrow frame design of GIM with assembly compatibility with the casing body, receiving high praise from users.

• LCD display
• Interior parts
• Other FPD related

【Customer Development Needs】 We received a request to minimize the bezel by integrating the display glass and resin frame through one-shot molding, in order to maximize the display without changing the size of the mobile device. 【More Specific Requirements】 There was a demand to enhance the precision of the glass insert, minimize the bonding area to the utmost, and ensure waterproofing. 【Our Proposal】 We jointly developed a binder printing that bonds with resin on the back of the glass along with decorative design, which is fused using the heat of the molded resin. We ensured quantitative management of the bonding strength and guaranteed waterproof performance through airtightness testing with specialized equipment. Utilizing the advantages of our in-mold transfer technology, we established a method where "the transfer does not occur on the glass but does on the resin frame," allowing for frame decoration during molding. 【Customer Evaluation】 We were able to provide a product with a narrow bezel and no gaps or steps between the glass and frame, which has been adopted by set manufacturers both domestically and internationally. Additionally, we received requests for not only flat glass inserts but also "bent glass" inserts, which were also adopted.

• Touch Panel
• LCD display
• Interior parts

**Customer Development Needs** We received a request to propose a new in-vehicle CID (Center Information Display) cover for vehicle OEM manufacturers, designed in a dome-shaped 3D format that cannot be achieved with glass bending, and to include optical processing and design elements. **More Specific Requirements** To approach the quality of a high-grade glass cover, the front side was required to have an AR (Anti-Reflection) coating, AFP (Anti-Fingerprint) coating, and a hard coat, while the back side needed a hard coat for outgassing prevention from molded resin, along with decorative design elements. **Our Proposal** We proposed inserting a hard coat sheet with AR/AFP on the surface and believed that the requirements could be met through in-mold transfer on the back side. We established a hybrid molding method that combines both elements and supplied the product. **Customer Evaluation** The product was able to achieve a shape that is impossible to process with bent glass while incorporating low reflection and anti-fingerprint features, resulting in great satisfaction. Based on the adoption of this for the customer's promotional in-vehicle CID module front cover, proposal activities to vehicle OEMs have commenced.

• Organic EL

**Customer Development Needs** We received an inquiry from a customer regarding a cover panel for in-car navigation with a unique 3D shape for exhibition purposes. **More Specific Requirements** The customer requested decorative embellishments on the back side of the cover panel to create a sense of "depth." **Our Proposal** Utilizing our double in-mold technology (which involves placing two films in the mold and performing simultaneous double-sided transfer decoration during shaping), we were able to perform simultaneous transfer decoration on both sides of the U-shaped panel, accommodating shapes that are difficult for secondary processing. Additionally, we applied our unique treatment to eliminate resin orientation distortion in the window area, making it compatible with polarized sunglasses. **Customer Feedback** We provided a prototype product, successfully participated in the exhibition, and received significant positive feedback, leading to an increase in concrete business negotiations and customer satisfaction. *You can view the catalog and case studies via "PDF Download."*

• Touch Panel
• LCD display
• Organic EL

**Customer Development Needs** We received a development offer for a business card case using our unique technology from a product planning company. **More Specific Requirements** They requested to use a special gimmick found in cosmetic compact containers for the main body and to apply separate gradients on both sides of the top part using a double in-mold technique. **Our Proposal** Leveraging our know-how in cosmetic compact design and manufacturing, we created a unique hookless opening and closing mechanism that appeals to men. The top part, which serves as the face of the product, employs a double in-mold technique, featuring a sense of depth with gradients and metallic embellishments. We developed a business card case that allows for infinite color variations through the combination of colored resin materials on the front and back of the top part. **Customer Evaluation** Since its launch in 2013, we have increased the color variations and sold over 40,000 units in total (as of the end of March 2021). In addition to general sales, we have numerous OEM achievements in collaboration with companies, including laser processing of characters and other designs on the top part.

• Office supplies and stationery
• Other contract services

**Customer Development Needs** We received a request from a customer dealing with glasses and sunglasses for a proposal for eyewear frames with decorative features that are not conventional. **More Specific Requirements** They requested a decoration that is covered by resin, rather than traditional methods like transfer or painting. **Our Proposal** We applied our development technology of "inserting transfer decorative molded products to encapsulate the transfer decoration" to explore sheets that can withstand the material requirements for eyewear frames. We proposed the idea of "inserting sheet insert molded products again to encapsulate the decorative sheet in resin." The decoration was implemented on the sheets using methods such as inkjet printing and vapor deposition, and we repeatedly prototyped to ensure it could withstand insert molding, ultimately achieving the specifications. **Customer Evaluation** Not only were we able to create a design for glasses with decorations that are completely sealed from external exposure and free from concerns about deterioration, but we also received high praise after exhibiting at a global eyewear and sunglasses trade show.

• others