三愛テクノロジー List of Products and Services

Here is an example of processing an injection molding mold for a storage case. Due to years of mass production, burrs had developed on the PL surface. As a response, we initially addressed this in-house with welding, then re-fitted it with hand processing by a finishing technician, and completed the project with in-house blasting. 【Case Overview】 ■ Name: Burr Repair for Storage Case Mold ■ Mold Type: Injection Molding Mold ■ Industry: Daily Necessities ■ Material: PXA30 ■ Size: 600×800×650 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

We would like to introduce a case study on the machining of injection molding molds for drawer storage cases. Burrs had occurred due to uneven thickness. As a permanent solution, we added an additional central inlay (from 2 locations to 3 locations) and increased the height of the inlay. After completing the work, we confirmed the trial at a mass production factory in Fukushima Prefecture. It seems that the permanent measures were effective, as the uneven thickness was eliminated, and no burrs were found, leading to mass production. 【Case Overview】 ■ Name: Adjusting uneven thickness in storage case mold ■ Mold Type: Injection molding mold ■ Industry: Daily necessities ■ Material: PXA30 ■ Size: 800×1150×1083 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

We would like to introduce a case study of processing injection molding molds for daily necessities (from another company). We received a request to change the surface finish of the product from a glossy specification (mirror polish) to a textured specification, and we commissioned an etching manufacturer to complete the work. 【Case Overview】 ■ Name: DIY Product Container Mold, Product Appearance Change ■ Mold Type: Injection Molding Mold ■ Industry: Daily Necessities ■ Material: S55C ■ Size: 600×650×600 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

Here are some examples of machining industrial injection molding molds (from other companies). This is a calendar that indicates the manufacturing year, which is common in molds. Initially, the calendar was engraved up to the year 2019, but since there was no calendar notation for the year 2020, additional calendar engraving was added for the years following 2020. Due to changes in molding materials, additional engraving was also carried out simultaneously. 【Case Overview】 ■ Name: Industrial Mold, Calendar (Engraving) Addition ■ Mold Type: Injection Molding Mold ■ Industry: Industrial Products ■ Material: PXA30 ■ Size: 550×650×650 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

Here is a case study of the machining of an injection mold for a cooler box. We received a report of an abnormality in the mold during mass production and promptly retrieved it. Upon inspection of the mold, we confirmed the damage of three inclined blocks. Since it was during mass production, we urgently manufactured and replaced the inclined blocks and delivered them. 【Case Overview】 ■ Name: Repair of damaged parts of leisure goods (cooler box) mold ■ Mold Type: Injection mold ■ Industry: Daily necessities ■ Material: S55C ■ Size: 600×800×560 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

This is a case of injection molding molds for interior parts used in electronic display boards. We received a request for texture processing, and since the parts are small, they wanted to assemble the inserts and perform the texture processing simultaneously. To achieve this, we conducted a disassembly cleaning that also served to remove oil residues. The texture processing was successfully completed, and the product was delivered. 【Case Overview】 ■ Name: Texture processing of interior parts for electronic display boards ■ Mold Type: Injection molding mold ■ Industry: Industrial products ■ Material: NAK55 ■ Size: 400×450×476 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

We would like to introduce a case study of an injection molding mold (from another company). Due to gas emitted from the resin causing product defects, we processed gas escape channels using a machining center. Since the resin is PC+ABS, we deepened the gas escape channel from the usual depth of 0.02mm to 0.05mm for reinforcement and checked for burrs using our in-house trial machine. After confirming that there were no issues, we delivered the product. 【Case Overview】 ■ Name: Gas Countermeasure Repair for Industrial Product Mold ■ Mold Type: Injection Molding Mold ■ Industry: Industrial Products ■ Material: PXA30 ■ Size: 500×500×450 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

This is a case study of machining an injection molding mold (other company’s mold) for automobiles manufactured overseas. The repair requests included burr repair, runner extension, and shape correction. For the burr repair, after laser welding, a finishing technician manually restored the joint and product areas. Notably, the runner extension was processed using a machining center. Regarding the shape distortion, it was caused by distortion during the initial polishing. Our polishing technician restored the shape while checking the 3D data. [Case Overview] ■ Name: Shape Repair of Molds for Automotive Parts ■ Mold Type: Injection Molding Mold ■ Industry: Automotive ■ Material: KP4M ■ Size: 570×700×720 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

This is a case of an injection molding mold (from another company) for automobiles manufactured overseas. Due to a request for burr repair, the upper surface of the inclined block in the center of the mold had a structure that contacted the cavity, but the adjustment of this inclined block was not done properly, which was the cause of the burr occurrence. Therefore, our company performed restoration of the fitting parts and product parts by hand after laser welding. 【Case Overview】 ■ Name: Burr Repair for Automotive Parts Mold ■ Mold Type: Injection Molding Mold ■ Industry: Automotive ■ Material: KP4M ■ Size: 650×1200×770 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

We would like to introduce a case of an injection molding mold (from another company) used for speakers at concerts and similar events. The speaker used for concerts had significant corrosion (rust) on the textured surface, so after removing the corroded parts with our polishing service, we performed re-texturing at the texture manufacturer. 【Case Overview】 ■ Name: Mold for music speakers, repair due to corrosion ■ Mold Type: Injection molding mold ■ Industry: Industrial products ■ Material: S55C ■ Size: 780×970×900 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract
• Calibration and repair

This is an example of an injection molding mold for products such as oil cans. The mold was produced in China in 2014, and over the years, burrs had developed on the product parts and PL surfaces. The molding operators were addressing this issue with burr removal using cutters, but due to the potential risk of injury, a repair was requested. In response, our company first conducted manual repairs in a short period, and after production stabilized, we performed further burr repairs and an overhaul of the mold. 【Case Overview】 ■ Name: Burr Repair for Storage Product Mold ■ Mold Type: Injection Molding Mold ■ Industry: Daily Necessities ■ Material: PXA30 ■ Size: 1030×1350×855 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract

Here is a case study of the processing of an injection molding mold for containers (storage products). This request came from a customer who wanted to change the size of the round rib located in the center. In response, our company filled the old shape with welding and then created the round rib shape of the desired size using a machining center. 【Case Overview】 ■ Name: Size Change of Round Rib for Container Mold ■ Mold Type: Injection Molding Mold ■ Industry: Daily Goods ■ Material: S55C ■ Size: 300×320×320 *For more details, please refer to the PDF document or feel free to contact us.

• Other molds
• Processing Contract

We would like to introduce a processing case of an injection molding mold (manufactured by another company) requested by a customer within the prefecture for industrial products. It is common for molds to have a calendar indicating the year of manufacture. Initially, the calendar was engraved up to 2019, but since there was no calendar notation for 2020, we added calendar engraving for the years following 2020. Due to changes in the molding materials, we also simultaneously implemented changes to the material markings through welding support. 【Case Overview】 ■ Name: Industrial Product Mold, Calendar (Engraving) Addition ■ Mold Type: Injection Molding Mold ■ Material: PXA30 ■ Size: 550×650×550 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of burr repair for a DIY product container mold that we conducted. The material is S55C, and the size is 500×600×450 for the injection mold. Burrs had occurred in the spool bush area, so we performed welding and finishing adjustments in-house before delivery. 【Case Overview】 ■ Name: Burr Repair for DIY Product Container Mold ■ Mold Type: Injection Mold ■ Material: S55C ■ Size: 500×600×450 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study of the processing of an injection molding mold for daily necessities (containers) requested by a customer within the prefecture. Due to burrs caused by wear on the sliding surfaces of the slides, repairs were carried out in-house through welding, machining, polishing, and finishing processes. Additionally, the overhaul of the hot runner was conducted by the manufacturer at the time of repair. 【Case Overview】 ■ Name: Burr Repair of Injection Molding Mold for Daily Necessities Containers ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 700×800×640 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We will introduce a case of replacement due to parts damage in the drawer storage case mold. During preparation before mass production, there was a mold drop that caused mold damage and broken guide pins. This incident occurred late at night, and we retrieved the mold the following morning. Since mass production could not be delayed, we removed the damaged guide pins and temporarily repaired the product's scratches by hand. We confirmed that there were no issues with delivery and mass production starting from the afternoon of the same day. Later, at the end of mass production, we replaced four guide pins and repaired the scratched areas again, completing the permanent work. 【Case Overview】 ■ Name: Replacement due to parts damage in the drawer storage case mold ■ Mold Type: Injection molding mold ■ Material: PXA30 ■ Size: 550×550×470 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

As a result of stopping operations for a week, when it was time to resume, rust began to appear on the product side. Coupled with the rainy season, while it did not reach the point of corrosion, everything was generally rusty. Since this was the start of mass production, we conducted polishing work in-house and provided urgent support within 6 hours. Therefore, although we received a request for mold maintenance on the morning of that day, we were able to resume mass production by 3 PM the same day. Our company also provides urgent support for mold maintenance like this. If you are having trouble with the maintenance of injection molding molds, please feel free to consult us. [Case Overview] ■ Name: Rust Repair for Storage Case Lid Mold ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 600×800×585 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case study on the machining of an injection molding mold for a storage case (drawer). We received a request from a customer stating that there were partial burrs on the product and they wanted repairs done before the burrs became larger. Therefore, we performed welding and machining (machining and electrical discharge) in-house and delivered the finished product. [Case Overview] ■ Name: Burr Repair for Storage Case Drawer Mold ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 600×700×594 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of burr repair for the storage case top mold that we conducted. We received a notification from the customer that burrs had occurred along the parting line due to years of mass production, and we carried out the repair. In-house, we performed welding, machining, and finishing. Since the product surface has a texture finish, we conducted blast treatment in-house to address this and delivered the product. 【Case Overview】 ■ Name: Burr Repair for Storage Case Top Mold ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 1000×1100×710 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

This is an example of a case where we adjusted uneven thickness at the request of a customer from Tokyo. Since it was a highly challenging request, we held multiple meetings with the customer and our design team to devise a solution. We made it possible to change the height of the insert in the center and installed a liner that allows for uneven thickness adjustment on the side of the insert, thereby resolving the uneven thickness issue. 【Case Overview】 ■ Name: Uneven Thickness Adjustment for Storage Case Outer Frame Mold ■ Mold Type: Injection Molding Mold ■ Material: PX-5 ■ Size: 950×950×1011 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of processing for medical-related molds that we have undertaken. We received a request from a customer in the prefecture, and since the mold was to be transferred overseas, we made modifications to create a concave shape in the product section. We handled a series of tasks in-house, including slide cores, movable inserts, strippers, welding, processing, and finishing, and delivered the final product. 【Case Overview】 ■ Name: Additional modification of concave shape for medical-related molds ■ Mold Type: Injection molding mold ■ Material: NAK80 ■ Size: 600×600×747 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of uneven thickness repair for a storage case mold that we conducted. We received a request from a customer in the prefecture, stating that the product part had uneven thickness, and we provided repair services. Adjustments were made using inlay parts, welding, and machining. 【Case Overview】 ■ Name: Uneven Thickness Repair for Storage Case Mold ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 600×700×594 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We carried out burr repair for the mold frame of a storage case at the request of a customer in Tokyo. After confirming the burr samples, we performed welding and machining (including machining and electrical discharge) in-house, followed by finishing. Since there were very delicate parts, we worked carefully and delivered the final product. 【Case Overview】 ■ Name: Burr Repair for Storage Case Mold Frame ■ Mold Type: Injection Molding Mold ■ Material: PX-5 ■ Size: 950×950×1083 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

This is a case study of repairing a manifold, which is a part used in a multi-point hot runner specification. We received a request from a customer in Yamanashi Prefecture who visited our website. They mentioned that they had previously repaired the manifold but were still experiencing resin leakage. We shaved down the area that appeared to have been previously repaired with welding, heated it with a burner, and then hammered the leaking resin area to create a dent before proceeding with the repair through re-welding. 【Case Overview】 ■ Name: Manifold Resin Leakage Repair ■ Mold Type: Injection Molding Mold Parts ■ Material: S55C ■ Size: 500*500*60 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study of burr repair for a part corresponding to the lower section of a bumper from a certain automobile manufacturer. At the request of a customer in Gunma Prefecture, we handled maintenance for a new model produced in South Korea. Due to the presence of burrs on the product section, we performed welding on the relevant areas of the mold, followed by finishing to align and complete the burr removal work. [Case Overview] ■ Name: Burr Repair for Bumper Surrounding Parts Mold ■ Mold Type: Injection Molding Mold ■ Industry: Automotive ■ Material: KP4M ■ Size: 1500*700*600 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of burr repair for the gate section of a part corresponding to the lower part of a bumper from a certain automobile manufacturer. At the request of a customer from Gunma Prefecture, we handled the maintenance of a new model produced in Korea. Upon investigation by our company, burrs were found in the gate section. The causes were identified as the weakness of the backup hill contact and the lack of contact on the bottom surface. Therefore, we performed welding on both the side and top surfaces of the mold, followed by reprocessing and fitting, and delivered the final product. 【Case Overview】 ■ Name: Burr Repair for Gate Section of Bumper Surrounding Parts Mold ■ Mold Type: Injection Molding Mold ■ Industry: Automotive ■ Material: KP4M ■ Size: 1500*700*600 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

This is a case study of a welding repair for the stripper plate's biting area in an injection molding mold used for plastic parts in medical devices. During mass production, the stripper bit, which caused production to stop, leading to a repair request to our company. Upon inspecting the mold, it was confirmed that the biting occurred precisely in the circumferential area of the product part, and burrs were also observed on the corresponding product section. Our company restored the biting and burr areas through welding and handled the delivery. [Case Overview] ■ Name: Welding Repair of Stripper Biting Area for Medical Device Mold ■ Mold Type: Injection Molding Mold ■ Industry: Medical ■ Material: PX-5 ■ Size: 600×600×747 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study of the repair of a battery cell frame mold's PL surface polishing, received from a molding manufacturer in Ibaraki Prefecture. The customer requested our services for mold repair due to the transfer of their production line, as the PL surface was loose, causing burrs on the resin molded products. We performed full surface polishing of the PL surface using a surface grinder, and also polished surrounding components such as slide rails, backup hills, and slide cores. This work involved strict tolerances of 0.005, but we measured the entire surface in advance and polished only the necessary areas to meet the tolerances. As a result, the finish was satisfactory to the customer. 【Case Overview】 ■ Name: Battery Cell Frame Mold PL Surface Polishing ■ Mold Type: Injection Molding Mold ■ Material: S55C ■ Size: 450*400*400 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of repairing resin leakage from the nozzle touch area of a speaker mold. This mold was transferred from mass production in China to Japan at the request of a customer from Yamagata Prefecture, and mass production is set to begin domestically. We were commissioned to conduct trials in-house. During a test trial to manufacture certified products, resin leakage occurred. Upon investigation, it was found that deformation had occurred at the nozzle touch area of the mold's spool bush. As a result, we performed cutting processing on our in-house lathe to rework the nozzle touch area. [Case Overview] ■ Name: Repair of resin leakage from the nozzle touch area of a speaker mold ■ Mold Type: Injection molding mold ■ Industry: Speaker ■ Material: S55C ■ Size: 650×400×410 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of repair for the crushed slide core PL surface in the main component of a medical waste bin mold. This mold was originally manufactured in South Korea and had been mass-produced in Japan for many years. However, burrs began to appear on the products, and maintenance of the mold was requested. Since mass production could not be halted, we received a request for slide core repair after accumulating a backlog of orders. We were given a week from pickup to delivery, during which we performed welding, fitting, and polishing, and delivered the repaired mold within a short timeframe. [Case Overview] ■ Name: Repair of crushed slide core PL surface in medical parts mold ■ Mold Type: Injection molding mold ■ Industry: Medical ■ Material: KP4 *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study of the repair of a damaged inclined slide for a large office multifunction printer mold cover. This mold was brought to us by a customer who reported that the inclined slide product part had been damaged during mass production. We considered repairing the damaged part through welding, but the thickness of the broken section was very thin, making it difficult to weld. After consulting with the customer, we decided to proceed with the production of a new mold this time. [Case Overview] ■ Name: Repair of Damaged Inclined Slide ■ Mold Type: Injection Molding Mold ■ Industry: Optical ■ Material: NAK *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of modification of the opening (round shape) of a mold for automotive fog lamp parts. This mold was manufactured overseas by the customer and then imported to Japan for use. During its use, the need for modification arose, and the customer contacted us. Although we had the mold drawings, since it was originally made overseas, we first measured the mold at our company before proceeding with the work. After that, we carried out modifications involving welding and delivered it in a form that satisfied the customer. 【Case Overview】 ■ Name: Modification of the product opening of a mold for automotive applications ■ Mold Type: Injection molding mold ■ Industry: Automotive ■ Material: KP4M *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study on the removal of rust caused by gas burning on a mold for printer parts. This mold was opened by the customer for use in mass production, but it was found to be unusable due to severe rust, leading them to request our assistance. Upon conducting an investigation while communicating with the customer, we identified that the corrosion was caused by gas. To remove the rust, we polished the mold and re-textured it before delivering it back to the customer. 【Case Overview】 ■ Name: Removal of rust caused by gas soot on a mold for printer parts ■ Mold Type: Injection molding mold ■ Industry: Optical ■ Material: NAK *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Here is a case study of the overhaul of a mold for speaker parts used in automobiles. This mold was transferred from a customer in China, and they requested us to perform an overhaul before starting mass production domestically. We disassembled the mold for the speaker parts, conducted a thorough cleaning, and replaced the worn-out components. As a result of this work, the customer expressed a desire to carry out mass production using our molding machines, and we decided to support them through to mass production. [Case Overview] ■ Name: Overhaul of Mold for Speaker Parts ■ Mold Type: Injection Molding Mold ■ Industry: Automotive ■ Material: S55C *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

We would like to introduce a case of rust repair due to water leakage in a speaker component mold used in automobiles. This mold was produced overseas for mass production by our client, and it was reported that water leakage occurred when it was transferred to Japan. They were looking for a mold manufacturer capable of handling repairs, and they contacted us. In response, we implemented a temporary solution by adding silicone on top of the O-ring to improve the sealing capability. Additionally, since corrosion (rust) had occurred in the cavity runner area due to the water leakage, we carried out repairs on that as well. [Case Overview] ■ Name: Rust repair due to water leakage in a speaker component mold ■ Mold Type: Injection molding mold ■ Industry: Automotive ■ Size: S55C *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Calibration and repair
• Other molds

Saniai Maxell Co., Ltd. specializes in the design and manufacturing of molds for plastic molding. We handle a variety of products, including automotive and industrial goods, office automation and home appliances, and everyday items. Additionally, we implement ideal designs for mold specifications during the design phase, taking into account factors such as flow analysis, and ensure that the mold design is sufficiently considerate of the mold materials. Please feel free to contact us with any inquiries. 【Business Activities】 ■ Design and manufacturing of molds for plastic molding *For more details, please download the PDF or feel free to contact us.

• Plastic Mould