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This time, I would like to share useful information about the lightweighting of precision sheet metal with everyone. To get right to it, what measures can be taken for lightweighting sheet metal? Generally speaking, for precision sheet metal made of stainless steel or iron, many people might think, "If we can change the material to lighter aluminum, it will become lighter." Indeed, aluminum has a lower specific gravity than other materials, so it is generally expected to be lighter. However, when it comes to precision sheet metal that involves welding, lightweighting is not so simple. I believe many of you may find this puzzling, so I will provide an example to explain. *For more details on the column, you can view it through the related links. If you have any questions, please feel free to contact us.*

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If we can achieve welding on thin plates, it will lead to weight reduction, as mentioned in previous technical columns. This time, I would like to share an example where we have achieved not only weight reduction through thin plate welding but also cost reduction. At Mazda Motor Corporation, we are actively working on proposals for weight reduction and cost reduction, leveraging not only our fine welding technology for thin plate welding but also our expertise in precision sheet metal. If you have any inquiries regarding cost reduction or weight reduction in precision sheet metal, please feel free to contact us. *You can view the detailed content of the column through the related links. For more information, please do not hesitate to reach out to us.*

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Dissimilar material welding is more challenging compared to welding materials of the same type, so it is necessary to consider this aspect in product design. In this column, we have compiled information that engineers designing products requiring dissimilar material welding may find useful. We hope you can make use of it. It is well known that welding can be accomplished between stainless steel and copper, which are different materials, but for other materials, especially rare metals, it is generally not known what can be joined together and what the strength will be. Designers considering dissimilar material welding should first grasp this information, as it will lead to smoother development. *For more details on the column, please refer to the related links. Feel free to contact us for more information.*

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At our company, which handles fine welding sheet metal, we often receive inquiries not only about welding but also about fine bending. There are cases where we are required to bend parts with rises of less than 1mm, such as in leaf springs. We perform bending processes with a minimum rise of 0.6mm, which is generally considered standard bending; however, many sheet metal workers are reluctant to take on such tasks. Why is that? The reason is that making this fine bending a reality is troublesome "before entering the bending process." *For more details on the column, you can view it through the related links. Please feel free to contact us for more information.*

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Titanium is lightweight and has high strength, and above all, it has the property of being rust-resistant, which is why it is used in various fields such as medical, aerospace, chemical, and semiconductor industries. However, on the other hand, it is also known as a difficult material to process, making it a challenge for us processors. This titanium, which is stable both mechanically and chemically, is considered a difficult-to-cut material due to its challenging nature in machining, and it is also very difficult in welding. In other words, while welding titanium to titanium is manageable, welding titanium to another material (dissimilar material welding) is fundamentally not possible, which has been a common understanding in the industrial world. *For more details on the column, please refer to the related links. For further inquiries, feel free to contact us.*

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The prices of essential goods such as food and gasoline have risen, making life more difficult. In the sheet metal industry as well, how to respond to the soaring material costs has become one of the major challenges. Therefore, this time, I would like to explain which thickness of stainless steel, a material whose cost has risen significantly, should be chosen in precision sheet metal work to keep material costs down. *For more details on the column, please refer to the related links. Feel free to contact us for more information.

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Precision sheet metal processing includes laser processing, press brake processing, and welding processing. This time, I would like to discuss press processing, which is suitable for small-scale production such as prototypes. As you may know, press processing involves plastic processing using molds and is widely used for mass-produced products such as automotive parts and industrial equipment. The key element of press processing is the "mold." In press processing, the cost of the necessary molds is undoubtedly a significant concern. For designers who need to create prototypes for product development, there is a mission to obtain prototypes with the same shape as mass-produced items as cheaply and quickly as possible. However, in the prototype process, the initial cost of the molds becomes a major obstacle. *For more detailed information, please refer to the related links. Feel free to contact us for more details.

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When designing devices and machines, it is necessary to design the shapes and dimensions of various components such as cutting, pressing, sheet metal, and resin according to the required functions and specifications. Naturally, if these components are set with high dimensional accuracy, it provides a margin in terms of specifications, which gives designers peace of mind. However, if this is overdone, costs will increase, so it is essential to maintain a moderate level of dimensional accuracy. Furthermore, regarding shapes, if the components are designed in a way that makes them difficult to process or requires complex procedures, not only will costs rise, but delivery times will also be extended. *Detailed content of the column can be viewed through the related links. For more information, please feel free to contact us.

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What we would like to introduce this time is about aluminum welding. At our company, we select suitable welding methods based on an understanding of aluminum's characteristics, optimizing the way heat is applied and dissipated to minimize distortion. Due to the unique properties of aluminum, the difficulty of welding is higher compared to stainless steel and iron. This time, we will introduce the specific properties of aluminum that make welding challenging, as well as the appropriate welding methods for aluminum. *For detailed content of the column, you can view it through the related links. For more information, please feel free to contact us.

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By switching from conventional processing methods to new techniques, there are often cases of cost reduction and quality improvement. For example, changing from machining to sheet metal processing plus welding often results in significant weight reduction and cost savings. In other words, it is very important to carefully consider the functions required of the processed products and select the appropriate processing method. In this column, we will share examples of method transitions that our company has actually implemented, so please use this as a reference. *For more details on the column, you can view it through the related links. For further inquiries, please feel free to contact us.

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As the miniaturization and weight reduction of components progresses, there is a growing demand for pipe products to be thinner, lighter, produced in small lots, or to have complex shapes. However, responding to these needs can be challenging with conventional processing techniques. Let me explain why this is difficult. When manufacturing non-standard cylinders/pipes, processes such as drawing, machining, and rolling are considered. Rolling is commonly used in sheet metal processing, but it often involves a machine known as a three-roll mill, where the material is bent as it passes between three rolls arranged in a triangular configuration. Consequently, numerous issues arise, such as leaving bending marks. *For more detailed information, please refer to the related links. Feel free to contact us for further inquiries.*

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Mazda Corporation is always focused on enhancing the product value for our customers and has made numerous VA/VE proposals to date. Our proposal capabilities have been recognized, and we have received inquiries from customers such as, "I would like to request this drawing for sheet metal processing." In such cases, we offer processing approaches unique to sheet metal work, and this time, I would like to introduce an actual case of our proposal. *For detailed content of the column, please refer to the related link. For more information, feel free to contact us.

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There are methods for joining two metal plates together, such as spot welding and seam welding (welding thicker sections). Additionally, non-welding methods include diffusion bonding and ultrasonic bonding. This time, we would like to introduce "through welding (stake welding)" as a new option for overlay welding. "I want to weld a 10mm flange, but it's too narrow for spot welding." "When I welded a different thickness part to a thin plate, it warped and bent." We will solve such problems. *For more details on the column, please refer to the related links. Feel free to contact us for more information.*

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Mazda Corporation has leveraged its advanced welding technology, cultivated through years of product manufacturing, to enable the welding of nickel plates to alkaline single cells, allowing for the creation of battery packs using methods other than spot welding. A battery pack is a combination of multiple single cells, capable of supplying a larger capacity of power than a single cell. As a result, they are used in products such as laptops and mobile phones. Here, we would like to introduce the welded products manufactured by our company. *For more detailed information, please refer to the related links. If you have any questions, feel free to contact us.*

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• Hydrogen battery

In the fabrication of pipes and chambers, advanced welding techniques known as water-tight welding (gas-tight welding) may be required. Water-tight welding is a welding technique designed to prevent leakage to the outside even when pressure is applied to a liquid in a sealed state. In particular, when welding thin plates, the melting drop becomes a challenge in ensuring water-tightness. This time, we will introduce the difficulties of water-tight welding and their solutions in a case study format. *For more details on the column, please refer to the related links. Feel free to contact us for more information.

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The contents and tolerances specified in the CAD drawings cannot be changed without the customer's consent. However, some CAD drawings we receive from customers may include designs that cannot actually be bent, or if processed forcefully, may result in deformation of holes or edges. This time, we will introduce the processing limits of sheet metal that fall under the category of "can be drawn in CAD but cannot be processed." *For more detailed information, please refer to the related links. Feel free to contact us for further inquiries.

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This time, as a special edition, we will deliver a report on the "Mechanical Elements Technology Exhibition 2024," which we recently participated in. 【Exhibition Overview】 Exhibition Name: Mechanical Elements Technology Exhibition (Monozukuri World) Dates: June 19 (Wednesday) - 21 (Friday), 2024 Venue: Tokyo Big Sight Total Number of Visitors: 69,717 (for the entire Monozukuri World) Compared to last year, the number of visitors has significantly increased, and the lively atmosphere typical of exhibitions has finally returned. Our company exhibited at the Shizuoka Prefecture booth, and the view from our booth was quite international, filled with a strong Asian presence from China, South Korea, and Taiwan. *For more detailed content of the column, you can view it through the related links. Please feel free to contact us for more information.

• Other machine elements

Typically, for products that cannot be addressed with bending processes, we may suggest welding. However, when it comes to considerations such as cost and appearance, as well as handling materials that are difficult to weld, we sometimes receive requests to strictly use bending processes. In such cases, we propose a "slit bending" process, where we create slits in the bending area before performing manual bending. By adopting the slit bending process, not only can we achieve a better appearance, but depending on the product, it can also lead to approximately a 15% reduction in processing costs. *For more details, you can view the related links. Please feel free to contact us for more information.*

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We received a disappointing message saying, 'While using it, a welding crack occurred...' When the product was delivered, it was properly welded, but it seems that during use, a welding crack developed. Upon inquiring about the situation of the crack, it appears that it was used in an area that experienced repeated loads, and since it was a small part that could fit in the palm of your hand, we had adopted a standard welding method, but that did not provide sufficient strength. Therefore, I proposed again, 'If that is the intended use, let's use this welding method and make this kind of repair.' *For more details on the column, you can view it through the related link. Please feel free to contact us for more information.

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A fitting is a component used to connect different parts, change the direction of pipes, or alter the flow rate. Fittings are classified based on their application, material, and shape, according to the following criteria: (1) Application: Changing flow direction, altering flow rate, merging or branching with other pipes, etc. (2) Material: SUS (stainless steel), copper, resin, etc. (3) Shape: Straight pipe fittings, elbow fittings, T fittings, etc. Connection methods for fittings include using pipe threads or connecting with bolts and nuts; however, these methods are not suitable when strength and reliability are required. Specifically, this applies in cases where a large supply of liquid or water tightness is needed. In such cases, welding is the preferred connection method. *For more detailed information, please refer to the related links. Feel free to contact us for further inquiries.

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Would you like to proceed with prototyping and development by combining thin plate welding processing for plates with a thickness of 1mm or less and dissimilar material welding? ■ Our company has accumulated know-how in dissimilar material welding with various combinations and performs welding tailored to the materials. - Nickel alloys, rare metals, etc. ■ We specialize in thin plate and micro welding technology, so you can also trust us with welding small chips such as sealing electrodes and ultra-thin pipes. For items whose weldability is unclear, we will conduct a sample trial (conditions apply). "Other companies wouldn't let me try, but they worked with me to confirm feasibility." "I had dissimilar material welding with a plate thickness of 0.3mm, and they were able to manufacture it." Many customers who inquire about dissimilar material welding start with "Can you do ~?" To turn our customers' ideas into reality, we sincerely engage in manufacturing, so please feel free to consult with us first!

• Circuit board design and manufacturing

This document is a design technical handbook that explains the key points that developers and designers should keep in mind to successfully create thin plate and fine welding sheet metal, where welding distortion is a concern. It has been supervised and produced by engineers who handle over 100 projects of thin plate sheet metal development annually. Thin plate sheet metal products are significantly influenced not only by the welding process itself but also by how they are designed from the development and design stages to ensure that the structure is suitable for thin plates and that the shape minimizes distortion. For example: 1. Achieving nearly zero gaps in the weld area through precise dimensional adjustments. 2. Reducing the welding sections to avoid distortion adjustments. 3. Designing to minimize the number of parts for easier processing. This handbook summarizes the key points of each process that developers and designers involved in precision sheet metal for thin plates should focus on, along with examples of VA/VE proposals. It contains valuable information that will surely be useful for your designs starting tomorrow! If you need it, please download it from the link below and make use of it. *The handbook is a digest version. If you would like the complete version, please contact us by phone. If you are having trouble with fine or thin plate welded products, please contact our company.

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New proposal! Full perimeter welding of 1mm square work size with joint attachment! No molds required, allowing for speedy and low-cost production for small lots. This greatly expands the possibilities for prototype development and design. We have specialized laser cutting machines and welding machines for thin sheet precision, so please leave the design of dedicated jigs, precise cutting, and welding to us.

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Our company offers "ultra-fine welding." With our unique thin plate welding technology and special fiber welding machines, we cater to extreme thin plate welding and fine welding. Specialized engineers in fine welding and thin plate welding handle everything from programming to unfolding, cutting, finishing, bending, and welding all at once. 【Features】 ■ Capable of ultra-thin plate welding from a thickness of 0.05mm ■ Trust us with micro and fine welding products as small as 1.0mm square ■ Accurate and precise welding made possible by in-house integrated design and manufacturing of jigs ■ Ultra-speed response ■ Introduction of microscopes and image dimension measuring devices ■ Numerous achievements in welding dissimilar materials such as rare metals *For more details, please refer to the PDF document or feel free to contact us.

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This catalog is the VA/VE Technology Handbook of Mazda Corporation, which offers stainless steel precision sheet metal processing services. It includes technical information for designers and developers on points of "high quality" and "low cost" design in thin sheet metal and welding, as well as points for VA/VE design in bending processes. [Contents (excerpt)] ■ What is precision sheet metal? ■ Various welding methods in precision sheet metal ■ Points for achieving both high quality and low cost in precision sheet metal ■ Stainless steel precision sheet metal VA/VE case studies ■ Information dissemination, etc. *For more details, please refer to the PDF document or feel free to contact us.

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This thin-walled pipe weldment connects pipes with diameters of φ2.0, φ2.8, and φ3.5, and is finished with overlay welding. The wall thickness of the pipes is very thin, ranging from 0.25 to 0.225, making processing difficult with standard welding methods. Furthermore, this thin-walled pipe is a product that requires airtightness, but by producing a fine bead as shown in the photo below, we can meet such requirements.

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We offer stainless steel precision sheet metal processing services. To design precision sheet metal at high quality and low cost, we consider processing steps such as cutting, bending, welding, and assembly during the design phase, allowing us to create excellent products. Please feel free to contact us with your requests. 【Features】 ■ Pursuing VA/VE proposals that enhance customer value ■ Capability to respond to "super" short delivery times and strict adherence to deadlines ■ We accept sheet metal production starting from one piece ■ A "super" versatile group specialized in small lot production *For more details, please download the PDF or feel free to contact us.

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