LSI Product Lineup

LSI Corporation is a group of experts in surface treatment, including mold polishing and mirror finishing. Our company is characterized not only by our ability to polish surfaces but also by our diverse processing technologies. We also support the production of mold components and the analysis and verification of prototypes using our well-equipped facilities and equipment. Please feel free to contact us when you need our services. 【Features】 ■ Equipped with diverse processing technologies, not just surface polishing ■ Capable of producing mold components and analyzing and verifying prototypes using advanced facilities and equipment *For more details, please refer to the PDF document or feel free to contact us.

In today's precision cutting processing, the characteristics of the mold surface are an extremely important factor that influences product quality. LSI Co., Ltd. derives its name from "Lapping Service Innovator" and provides specialized technology that not only achieves a mirror finish but also removes machining marks while maintaining dimensional accuracy and shape. While there are many polishing companies for general resin molds, our strength lies in our specialization in polishing high-difficulty press molds and forging molds. Through our unique know-how tailored to specific applications (bending, drawing, shearing, etc.), we achieve surface characteristics at a higher dimension that machines cannot reach. *For details on our polishing technology that dramatically changes the lifespan of press molds, please download our materials for confirmation.

Shearing processing applies strong localized stress, so the wear of the mold directly affects the product dimensions. By polishing the surface of the mold to a smooth finish, it is possible to reduce friction resistance with the metal sheet and improve the quality of the shearing surface. Additionally, maintaining uniform edges on the punch and die reduces cutting resistance, achieving both improved processing efficiency and longer mold life. In particular, aligning the sliding direction with the polishing marks minimizes wear. *Please refer to the materials for detailed points on polishing that directly address issues in shearing processing.*

The edge treatment of punches and dies in shearing processes is key to extending tool life. By applying fine R (radius) treatment and chamfering to the edges, we can suppress burr generation and effectively prevent chipping. Our company eliminates the difficulties of R penetration and variation that are challenging in machining through skilled "polishing" techniques, forming a uniform mirror-finished R around the entire circumference. This smooth finish achieved through manual processing removes the starting points of wear and supports stable machining. *Examples of the artisan's skill in "phase alignment" and R processing can be confirmed through document downloads.

Even with an expensive PVD coating, if the condition of the substrate is poor, the original performance cannot be exhibited. To ensure a uniform coating film and enhance adhesion, polishing the surface of the mold, which serves as the substrate, is essential. If the surface has bumps and irregularities, stress will concentrate, making the film more likely to peel off; however, a smooth substrate allows for a consistent film thickness. Additionally, by removing the processed altered layer (white layer) created by wire processing through polishing, we can prevent poor film formation and establish a stable surface. *Details on management items to maximize the effectiveness of the coating are explained in the materials.

This is a case where we struggled with secondary shearing and chipping during the processing of 4.5mm thick plates (SAPH-440-OD). Traditionally, maintenance was required after about 20,000 shots, but our company proposed and implemented a micro R treatment on the cutting edge and polishing before and after coating. As a result of changing the coating type to AICrN, the tool life was extended to an astonishing 150,000 shots. This is a good example of achieving stabilization of part accuracy and reduction of total costs through the optimization of polishing technology. *Please download the materials to check the specific processing conditions and process charts that led to this dramatic improvement.

Coating using the arc ion plating method tends to worsen surface roughness after application. Due to the influence of droplets generated during coating, the surface may become approximately Rz1.0 rougher than the original, leading to early galling and variations in lifespan. Our company improves the roughness to Rz0.353 by incorporating a "polishing" process after coating, dramatically enhancing lubricity. This combination of "pre-polishing + post-polishing" is extremely effective for protecting molds in harsh pressing environments. *Detailed data on the transition of surface roughness (after processing → polishing → coating → post-polishing) is available in the documentation.

To achieve both improved product quality and cost reduction in press processing, managing the surface condition of molds, particularly the "polishing," is essential. This document delves into the role of polishing in press molds from the perspective of reducing secondary processing efforts through friction reduction and improving processing efficiency. In particular, when applying PVD coating, it explains in detail how the underlying surface roughness affects the adhesion and lifespan of the film, along with the mechanisms involved. This book is packed with essential knowledge for suppressing variations in mold lifespan and establishing a stable production system. *Please feel free to download the explanatory material summarizing practical polishing tips that can be immediately useful on-site for free.*

The edge shape in shearing processing is not simply about being sharp. Rather, appropriate treatment is the key to longevity. Applying a fine R treatment to the punch edge is extremely effective for chipping prevention and burr suppression, but its quality heavily depends on the operator's "polishing" skills. Our company provides a smooth and uniform R shape that can only be achieved through manual processing, thanks to strict management using phase alignment and contour shape measuring machines, thoroughly eliminating the starting points of wear. This enables high-dimensional durability that was difficult to achieve with conventional processing machines, as well as ensuring a stable shearing surface. *Please obtain our free materials that explain in detail the dramatic effects of edge treatment on tool life right now.

LSI Corporation is a professional group specialized in "hand polishing" of press mold parts and machine parts. In recent years, the increase in difficult-to-process materials such as high-tensile steel, titanium, and aluminum in mold manufacturing has led to challenges that cannot be addressed solely through design and manufacturing ingenuity. The company proposes precise finishing through skilled manual work, significantly improving the durability (lifespan) of molds and the effectiveness of coatings. They offer unique technologies that can accommodate complex shapes like gears, which cannot be easily replicated by other companies. *For detailed information on the artisan technique of "hand polishing," please download and check this document.*

In the mold industry, "polishing" is an extremely important process that affects product quality and production costs. The minute irregularities on the surface of molds and workpieces generate localized pressure during pressing, leading to adhesive wear and seizing. By thoroughly removing these surface irregularities with skilled techniques, it is possible to prevent these issues in advance and significantly extend the lifespan of molds. The reliable technological capabilities of LSI are attracting considerable attention from many mold manufacturers. *For details on the effects of "polishing," which directly relates to cost reduction in molds, please refer to the materials.

Even with existing mold components, there are cases where dramatic performance improvements have been achieved through re-polishing of LSI. In one instance with a punch component, there were issues with burr formation on the work cross-section, and the shot count was limited to around 10,000 to 20,000 shots. By applying a precise curve (R) to the cutting edge of the punch, the company improved the sliding properties and successfully eliminated the burrs. As a result, the manual burr removal process was reduced, and the shot count dramatically increased to 150,000 shots. *Details of successful cases including specific improvement figures are available in a full-color document.

The polishing of LSI is mostly done by skilled artisans, capable of handling complex shapes that machines would typically reject. Even for intricate shapes like shear punches and gears, we achieve the desired precision by utilizing grinding stones, buffs, and sometimes even bamboo or disposable chopsticks. While it does not require large-scale equipment, we have introduced advanced devices such as 3D measuring machines and contour tracers to ensure precision at the micrometer level. We provide high value-added processing that merges the artisan's intuition with advanced measurement data. *Details of our track record in handling complex shapes and our precise measurement system can be found in the documentation.

Not only do we provide polishing process outsourcing, but LSI has also established a support system from the design stage. In the production of new mold parts, we consistently support the design of "polishing allowances" considering ease of polishing and precision, as well as the selection of coatings and materials. Additionally, we are capable of "reverse engineering," which involves measuring existing parts and creating drawings. By designing in-house and processing through a reliable network of partner manufacturers, we respond to a wide range of customer needs with a one-stop solution. *For details on our total solution that optimizes everything from design to processing, please refer to the materials.

At LSI, both young and veteran professionals are honing their skills daily as "pros" in their respective fields. From the very beginning of his employment, Mr. Norinobu Onishi has continued to learn the art of hand polishing, and in the manufacturing area, there is a constant awareness that "no two parts are the same" as they engage with the blueprints. A meticulous attention to detail that does not rely on past experiences and does not overlook tolerances measured in micrometers supports the company's high reliability. Through collaboration with the design group, which values the voices from the field, we consistently deliver high-quality products that are continually refined. *We are distributing interview materials that detail our efforts in technical inheritance and the thoughts of our staff.

We would like to introduce a case where we solved the customer's issue of "unable to manage the dimensions and shape of parts that require surface treatment." In response to the problem of shape distortion and deviation from dimensional tolerances due to LAP and coating, we manufactured the parts including coating from processing. We provided dimensional indications prior to processing and managed dimensions at the micrometer level using our LAP. By incorporating the coating into the dimensions requested by the customer, we achieved longer service life, stabilized production numbers, increased production volume, reduced costs, and decreased the frequency of part replacements. 【Case Summary】 ■ Issue - Unable to manage the dimensions and shape of parts that require surface treatment ■ Proposed Solution - Manufactured parts including coating from processing ■ Results - Increased production volume, reduced costs, decreased frequency of part replacements *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved the customer's issue of "poor mold retention." The customer was experiencing problems with early-stage scratches and wear despite coating, leading to poor mold retention and low shot counts. We proposed WPC treatment. As a result, the coating became more resistant to peeling, and scratches decreased, leading to its adoption. The shot count more than doubled, and mold retention improved. 【Case Summary】 ■ Problem - Poor mold retention ■ Proposed Solution - Proposal for WPC treatment and polishing before and after WPC ■ Results of Implementation - Reduction in scratches and wear, shot count more than doubled, and improved mold retention *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issue regarding "mold lifespan." The customer consulted us about the short lifespan of punches, and we suggested enhancing the polishing before coating. Changing the material or coating carries risks, but since we only modified the polishing, they felt comfortable trying it out. After changing the Rz from around 3 to 0.8, the number of shots increased, product accuracy improved, and costs were reduced. 【Case Summary】 ■ Issue - Mold lifespan ■ Proposed Solution - Enhanced polishing before coating ■ Results - Increased number of shots, improved product accuracy, and reduced costs *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we resolved the issue of "frequent deficiencies in drawings and specification changes leading to rework" that our customer faced. To address the problem of rework causing delays in delivery and additional costs, we proposed pre-support for drawing checks and specification confirmations. With a large number of partner manufacturers and the ability to cover a wide range of fields, we were chosen as an easy-to-consult partner. As a result, rework was significantly reduced, and delivery delays became almost nonexistent. 【Case Overview】 ■ Issue - Frequent deficiencies in drawings and specification changes leading to rework ■ Proposed Solution - Pre-support for drawing checks and specification confirmations ■ Implementation Results - Rework was significantly reduced, and delivery delays became almost nonexistent *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issue of "tight deadlines that existing partner companies cannot handle." Our company offers a manufacturing system capable of short lead times and urgent responses, along with a one-stop solution utilizing numerous partner manufacturers. After implementation, rework significantly decreased, and delays in delivery became almost nonexistent. Additionally, we became capable of handling sudden projects, which reduced the burden on our internal teams. [Case Overview (Partial)] ■ Problem - Rework is causing delays in delivery and additional costs. - Variability in quality is increasing complaints and the burden of re-inspections. ■ Solution - Proposed changes in processing methods and alternative materials to shorten the process. - Established a system that allows for immediate response in case of defects, addressing issues through corrections rather than re-manufacturing. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved the customer's issue of "having few companies that can respond to urgent requests." Our company offers a manufacturing system capable of short lead times and urgent responses, along with a one-stop solution utilizing numerous partner manufacturers. We have received positive feedback for our continuous improvement proposals, such as cost reduction and lead time shortening, which has enabled us to handle sudden projects and reduce the burden on our internal teams. [Case Overview (Partial)] ■ Issues - Delays and additional costs are occurring due to rework. - The burden of complaints and re-inspections is increasing due to quality variability. ■ Solutions - Utilizing our network of partner manufacturers to select suitable processing locations. - Proposing changes in processing methods and alternative materials to shorten lead times. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we resolved a customer's issue of "being asked to reduce costs but not being able to come up with improvement proposals." Faced with the problem of not being able to find specific measures for cost reduction, which was putting pressure on profits, we proposed a one-stop solution utilizing processing methods and materials that lead to cost reduction, along with numerous partner manufacturers. As a result, the stability of quality led to shorter inspection times and a decrease in complaints, and we received many positive comments such as "easy to consult" and "quick response." [Case Overview (Partial)] ■ Issue - Being asked to reduce costs but not being able to come up with improvement proposals ■ Proposed Solution - Proposal of processing methods and materials that lead to cost reduction ■ Implementation Results - Stability of quality led to shorter inspection times and a decrease in complaints *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved the customer's issue of "difficulty in meeting the surface roughness and shape tolerances specified in the drawings." There are often cases where trying to meet the surface roughness leads to distortion of the shape, and trying to maintain the shape results in failing to meet the surface roughness. In response to this problem, we proposed a method of performing polishing based on the contour measurement values obtained from a three-dimensional measuring machine. With a robust inspection system that allows for accurate measurements and reliable polishing techniques, we were able to implement this solution. As a result, our internal technical capabilities have improved, and we have been able to take on more challenging projects. [Case Overview (Partial)] ■ Issue - Difficulty in meeting the surface roughness and shape tolerances specified in the drawings. ■ Proposed Solution - Suggesting the necessary allowances and roughness for polishing during the work production stage. - If the sales department places a production request, it becomes easier to specify the required allowances and roughness. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issues regarding "polishing gear shapes." In response to problems such as lack of polishing staff, not knowing how to polish, taking too long for polishing, and not achieving the required precision and surface roughness, we proposed the necessary tools, equipment, and years of know-how for polishing. Customers appreciated our ability to maintain precision even with short lead times, which has allowed us to receive various polishing projects. 【Case Overview】 ■ Issues - Polishing gear shapes ■ Proposed Solution - A specialized system for polishing is in place ■ Results - We have been able to receive various projects *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved our customer's issue of wanting to "extend the lifespan of their molds." In response to the problem of poor mold durability due to friction, wear, and galling, we proposed polishing that maintains the shape and improves surface roughness. By enhancing the adhesion of the coating through polishing, we improved the surface roughness while maintaining the shape, resulting in more than double the number of shots. 【Case Overview】 ■Issue - Wanting to extend the lifespan of molds ■Proposed Solution - Polishing that maintains shape and improves surface roughness ■Results - More than double the number of shots *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issues regarding "maintenance polishing." In response to problems such as short mold lifespan, high costs for creating new molds, and the inability to perform maintenance polishing in-house, we proposed maintenance polishing after coating removal and a new type of coating film. As a result, requests for maintenance polishing increased, leading to successful cost reductions, and we also received requests for new polishing. 【Case Overview】 ■ Issues - Maintenance polishing ■ Proposed Solutions - Adhesion removal - Restoration of deformed shapes - Improvement of surface roughness *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's problem of "the company they had been requesting processing from has gone out of business." In response to issues such as other companies not matching the same quality and production costs, and the lack of drawings, we proposed to align quality and costs while creating drawings based on our design. By being able to handle items without drawings, we also received inquiries about parts from other departments that lacked drawings. 【Case Overview】 ■Problem - The company they had been requesting processing from has gone out of business. ■Proposed Solution - After multiple meetings, we proposed parts that matched the customer's needs. ■Results - We were able to handle items without drawings. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study in which we solved the customer's issue of "not being able to do 3D design." In the design and production of robotic hands, the new model's work shape became complex, making it impossible to address the issue with conventional 2D design. We proposed a concept using a 3D model instead of drawings. By making a speedy decision on the concept, we were able to shorten the lead time to the finished product, and we have since received requests for other projects as well. 【Case Overview】 ■ Issue - Unable to do 3D design ■ Proposed Solution - Provided a 3D model to visually convey the concept and conducted web meetings ■ Implementation Results - Shortened lead time to the finished product due to speedy decision-making on the concept *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved our customer's problem of "troublesome process management." In response to the issue of having to manage and arrange delivery dates for each supplier, we proposed a comprehensive management solution from materials to coating by listening to their desired delivery dates and requests. This reduced the time spent on arrangements, allowing them to dedicate more time to other tasks. 【Case Overview】 ■Problem - Troublesome process management ■Proposed Solution - Comprehensive management from materials to coating ■Results - More time available for other tasks *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issue of "poor service from competitors in single part sales." In response to problems such as slow response speed, limited information retrieval, and sales unable to provide immediate answers regarding price and delivery time, we proposed quicker quotation responses, better proposals, and faster delivery times. As a result, customers who placed an order once continued to place orders and maintained a high priority for their requests. [Case Overview (Partial)] ■Issue - Poor service from competitors in single part sales ■Proposed Solution - Quotation within 24 hours ■Implementation Result - Customers who placed an order once continued to order and maintained a high priority for their requests. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issue of "not being able to meet the surface roughness specified in the drawings." In machining, we were unable to meet the required surface roughness, and there was also the problem of not having skilled technicians for polishing. We proposed a fully manual polishing process using specialized tools and equipment. The quality, standards, and speed of delivery exceeded the specifications that could not be met through machining, and the customer was satisfied. 【Case Overview】 ■Issue - Unable to meet the surface roughness specified in the drawings ■Proposed Solution - Fully manual polishing using specialized tools and equipment ■Results - We were able to quickly propose a solution, leading to an increase in polishing requests. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we resolved a customer's issue of "production being at risk of stopping due to the damage of mold components." By fully utilizing our network, we simultaneously produced a temporary solution using pre-hardened steel and the regular material. As a result, we were able to replace the damaged parts without halting production. 【Case Overview】 ■ Issue - Production was at risk of stopping due to damage to mold components. ■ Proposed Solution - Simultaneous production of a temporary solution using pre-hardened steel and the regular material. ■ Outcome - We were able to replace the damaged parts without stopping production. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we solved a customer's issue of "unable to strip the coating from carbide" at our company. In response to the problem of having to discard items after a single use, we proposed a method to remove the coating through polishing. This has made reprocessing possible and has helped reduce the costs of new production. 【Case Overview】 ■Issue - Unable to strip the coating from carbide ■Proposed Solution - Remove the coating through polishing ■Results - Reduced costs of new production *For more details, please download the PDF or feel free to contact us.

In the automotive industry, there is a demand for longer-lasting parts and cost reduction. Particularly for parts that are prone to wear or are designed for reuse, issues can arise with coating delamination and reprocessing. When it is difficult to remove hard coatings, it can lead to the disposal of parts and an increase in the costs of new production. Our company proposes a solution to this challenge through coating delamination via polishing. This enables the reprocessing of parts and contributes to the reduction of new production costs. 【Application Scenarios】 - Reuse of worn mold parts - Regeneration of parts with difficult coating delamination - Parts management aimed at cost reduction 【Effects of Implementation】 - Reduction of new production costs - Effective utilization of parts - Contribution to waste reduction

In the semiconductor manufacturing industry, mold modification requires precise processing and longevity. In particular, the delamination of hard coatings is highly challenging, and if proper treatment is not performed, it may lead to the disposal or new production of molds. This can result in increased costs and potential impacts on production plans. Our company proposes polishing for the delamination of hard coatings, addressing the customer's challenge of being unable to delaminate hard coatings. This enables the reprocessing of molds and contributes to reducing new production costs. 【Usage Scenarios】 - When delaminating hard coatings is difficult - When wanting to avoid mold disposal - When wanting to reduce new mold production costs 【Effects of Implementation】 - Enables the delamination of hard coatings - Reduces new production costs through mold reuse

In the mold manufacturing industry, there is a demand for longer mold lifespans and cost reduction. In particular, the difficulty of coating removal from carbide materials can lead to mold disposal, which increases the costs of new production. Our company proposes a method to remove coatings from carbide materials through "polishing." This enables the reprocessing of molds and contributes to the reduction of new production costs. 【Usage Scenarios】 - When coating removal from carbide materials is difficult - When considering the reuse of molds - When wanting to reduce new production costs 【Benefits of Implementation】 - Enables the reprocessing of molds - Reduces new production costs - Decreases disposal costs

In the cutting tool industry, extending the life of tools through regrinding is essential for maintaining performance and reducing costs. Particularly, coatings applied to carbide tools can be difficult to remove during regrinding, leading to cases where tools are discarded. The challenge of being unable to remove coatings can prevent the full utilization of a tool's lifespan and potentially increase the costs of new purchases. Our company proposes a unique method of coating removal through our proprietary "polishing" technique to address this issue. 【Usage Scenarios】 - Regrinding of carbide-coated tools - Processing of tools with difficult-to-remove coatings - Cost reduction through the extension of tool life 【Benefits of Implementation】 - Enables coating removal, allowing for the reuse of tools through regrinding - Reduces the costs of producing new tools - Contributes to the reduction of the lifecycle costs of tools

In the aerospace industry, maintaining the performance of precision jigs and managing costs are essential. In particular, carbide jigs with special coatings may require reprocessing due to wear and degradation, but the difficulty of coating removal presents a challenge. If coating removal is not possible, it may necessitate the disposal or new fabrication of the jigs, potentially leading to increased costs. Our company proposes coating removal through polishing to address this issue. 【Application Scenarios】 - Coating removal of carbide jigs - Cost reduction through jig reuse - Containment of new fabrication costs 【Benefits of Implementation】 - Enables reprocessing of jigs - Reduction in new fabrication costs - Contributes to the longevity of jigs

In the medical device industry, particularly in implant polishing, precise surface treatment is directly linked to the performance and safety of products. When coating removal is difficult, it leads to situations where reprocessing is not possible, forcing reliance on new production, which contributes to increased costs. Our company proposes a unique coating removal method through our proprietary "polishing" to address the challenge of "unable to remove hard coatings." This enables the reprocessing of implant components and helps reduce the costs of new production. 【Application Scenarios】 - Coating removal of implant components - Surface preparation before re-polishing - Coating removal from prototypes 【Benefits of Implementation】 - Reduction of new production costs - Promotion of component reuse - Shortening of lead times

In the energy industry, particularly in the field of turbine blades, coatings are sometimes applied to enhance the durability and maintain the performance of components. However, once a coating is applied to hard materials, its removal can be challenging, and in many cases, it cannot be reprocessed, leading to the necessity of disposal. This presents a challenge in terms of increasing costs for new production and effective resource utilization. Our company proposes a unique coating removal method through our proprietary "polishing" technique to address the issue of "inability to remove coatings from hard materials." This will enable the reprocessing of components such as turbine blades and contribute to reducing costs for new production. [Application Scenarios] - Coating removal from turbine blades - Hard components requiring reprocessing [Benefits of Implementation] - Reduction in costs for new production - Improved resource efficiency through component reuse