サトウパック List of Products and Services

We handle injection molding (injection molding) as well as vacuum forming so that our customers can directly compare and examine both methods. Typically, mesh parts are commonly produced by insert molding mesh sheets; however, it is possible to mold resin parts using only injection molding without insert molding. This leads to benefits such as cost reduction for mesh parts and cost savings from the reduction of assembly processes. [Benefits] - Cost reduction for mesh parts - Cost savings from the reduction of assembly processes, etc. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Injection molding typically requires products to be shaped in a "one-directional" manner, similar to removing a pudding from a mold, allowing for easy ejection. However, with special molds, "three-dimensional" ejection becomes possible. By replacing connection parts that were traditionally made by bending rubber tubes with resin molded products, the number of components can be reduced. Furthermore, the assembly process is also simplified, enabling cost reduction. 【Features】 ■ Special molds allow for "three-dimensional" ejection ■ Assembly processes are simplified, enabling cost reduction ■ Special molds enable integrated molding *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company offers injection molding (injection molding) and vacuum forming so that customers can directly compare and examine both methods. In "Injection Molding of Thermoplastic Elastomer Resin," we mold resin with the elasticity of rubber, known as thermoplastic elastomer (TPE). As resin molded products that utilize the properties of rubber, they are used in applications such as seals and cushions. 【Features】 - Molding resin with the elasticity of rubber = thermoplastic elastomer (TPE) - Used as resin molded products that take advantage of rubber properties, such as seals and cushions - Generally reduces processes compared to rubber manufacturing - High cost performance - Cost reduction by replacing rubber parts with elastomer molded products *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Vacuum-formed trays are also packaging materials, and we handle various other packaging materials as well. We can offer cardboard boxes and plastic corrugated boxes as outer packaging for vacuum-formed trays, available as a set. We also accept orders for individual items such as plastic bags, cushioning materials, and stretch film. In addition to vacuum forming, we also provide dividers made of foam and cardboard. We will work with you to consider and propose appropriate divider materials and systems based on the required specifications and sizes of your products. 【Packaging Materials Lineup (Excerpt)】 ■ Bubble cushioning material ■ Bags for bubble cushioning material ■ Bag processing for cross-linked polyethylene sheets ■ Cardboard boxes ■ Cardboard boxes for inner packaging *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Cushioning material

"Thermal pressure molding" involves filling polyethylene foam products into a dedicated mold, applying heat and pressure to shape them. It can be molded in three dimensions from simple to complex shapes, and insert molding with hardware, core materials, and other materials is also possible. The characteristics of polyethylene foam, such as "high cushioning and shock absorption" and "floating in water due to being an independent foam," are directly reflected in the molded products. 【Features】 ■ Molded products that retain the characteristics of polyethylene foam ■ Capable of three-dimensional molding from simple to complex shapes ■ Insert molding with hardware, core materials, and other materials is also possible ■ Suitable for low-cost, small-lot production ■ Color options available, including red, blue, yellow, green, black, and white *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

At Sato Pack, we utilize the lightness, thermal insulation, and cushioning properties of expanded polystyrene for various applications, not only as packaging materials but also as industrial components. In addition, instead of molding with molds, we can create various shapes by cutting and gluing sheets of expanded polystyrene. "Expanded polystyrene" refers to polystyrene beads that have been expanded, but there is also expanded polypropylene made from expanded polypropylene beads. 【Features】 <Expanded Polystyrene Board Products> ■ It is possible to create various shapes by cutting and gluing sheets of expanded polystyrene. <Bead Expanded Polypropylene> ■ The bonding of the expanded beads is strong, and there is little debris from broken beads. ■ The appearance has more luster on the surface compared to expanded polystyrene. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Cushioning material

Die-cut products utilize various materials, either individually or in composite forms, and are used as auxiliary components such as gaskets, spacers, and cushioning parts. In the example of "die-cut products made from PP (polypropylene) sheets," a die-cut thickness of 3mm is achieved using a Thomson die. While there may be some whitening and burrs, the attractive point is the low initial cost. Sato Pack proposes the final shape considering the assembly efficiency, processability, and mass production capability of our customers. Please feel free to contact us when you need assistance. 【Case Summary】 ■ Achieved a die-cut thickness of 3mm using a Thomson die ■ Some whitening and burrs present ■ The low initial cost is an attractive point *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Die-cut products utilize various materials, either individually or in composite forms, and are used as auxiliary components such as gaskets, spacers, and cushioning parts. In the example of "die-cut products made from EPT foam (synthetic rubber)," gaskets with a width of 1mm are cut from a 2mm thick EPT foam sheet. Sato Pack proposes the final shape considering the assembly efficiency, workability, and mass production of our customers. Please feel free to contact us when you need assistance. [Case Overview] ■ Application: Gasket ■ Gaskets with a width of 1mm are cut from a 2mm thick EPT foam sheet. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Sato Pack is capable of producing "die-cut products made from sheets laminated with polyethylene foam and double-sided tape." By creating a sheet with the product on a release paper, handling during the assembly process becomes easier. We will make proposals while comparing costs and work efficiency, such as the number of pieces from raw materials and the number of pieces per sheet. Please feel free to contact us when you need our services. 【Case Overview】 ■ By creating a sheet with the product on a release paper, handling during the assembly process becomes easier. ■ We will make proposals while comparing costs and work efficiency, such as the number of pieces from raw materials and the number of pieces per sheet. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

"Die-cut products" are processed from various materials, both individually and in composite forms, and are utilized as auxiliary components such as gaskets, spacers, and cushioning parts. We can match the physical properties and characteristics of various materials with the specifications required by our customers, while also considering processability and mass production, to propose appropriate materials. Additionally, methods for die-cutting without incurring initial costs include reciprocating cutter processing and water jet processing. [Materials] ■ Double-sided tape ■ Polyethylene foam ■ Cushioning material ■ Sponge ■ Resin board, resin sheet *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Here is an introduction to the basic flow of launching an automated tray. We will conduct a meeting to discuss the requirements for the automated tray specifications, such as static prevention and conductivity levels, and create drawings. Once the 2D and 3D data of the completed drawings are prepared, we will have the customer review and approve the drawings. We will conduct a prototype of only one section of the tray to confirm the shape and fit of the components, and then proceed to mass production. 【Flow】 ■1. Meeting on automated tray specifications ■2. Drawing creation ■3. Drawing approval ■4. Prototype production ■5. Start of mass production ■6. Production and delivery of mass-produced items *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

In recent years, in order to reform work styles and achieve cost advantages over competitors, there has been an increasing movement towards automation in the manufacturing process, utilizing various assembly robots and industrial robots. With the rise of automation, we have received many inquiries about high-precision automation trays used by industrial robots when picking up parts. By engaging with customers from various fields in the development of automation trays, our company has been able to acquire a wealth of know-how. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

Here is the flow of custom tray production. Based on the actual products and drawings to be housed in the tray, we design the tray. During the design process, we confirm the details of the tray's usage conditions. We create a prototype (one piece) to check the fit between the tray and the product. After that, we proceed to make the production mold and create the cutting die. 【Details to Confirm Regarding Usage Conditions】 ■ Size of the tray (handheld size? Is there a container for the tray?) ■ Number of tray masses (the production lot of the products to be housed in the tray, a manageable number within the process...) ■ Thickness (considering necessary strength, fit requirements, and costs) ■ Orientation of the products in the tray, including the accommodation of set parts ■ Need for stacking *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Vacuum forming is particularly good for large trays with thicknesses up to 6.0t. Compared to injection molding, molds can be made at a lower cost, providing cost advantages. Additionally, the delivery time for molds can be shorter than that of injection molding. Please feel free to contact us when you need assistance. 【Product Examples】 ■ Kaidac 3.0t ■ Thick trays PPN 3.0t *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

We can also propose higher-function trays equipped with scratch prevention and wobble prevention features. Vacuum forming of composite materials such as foam resin sheets, resin sheets + non-woven fabric, and resin sheets + foam resin. For example, by adding a non-woven fabric layer to PET resin, which has good moldability, we can enhance scratch prevention effects. 【Product Examples】 ■ Vacuum-formed trays made of foam PP sheets - Trays with cushioning and scratch prevention functions ■ Composite material trays of non-woven fabric + PET - Adding a non-woven fabric layer to PET resin, which has good moldability, enhances scratch prevention effects ■ Foam polyethylene trays - Trays for preventing scratches on precision parts *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

At Sato Pack, we offer vacuum forming for "lidded trays." Trays similar to carry cases are also possible. Additionally, with a fitting of uneven surfaces, the lid can be secured tightly. By selecting materials according to the characteristics and requirements of the target parts, we customize trays with high functionality. Please feel free to contact us when placing an order. 【Features】 ■ Customizable trays with high functionality ■ Ability to change tray functions by selecting materials according to specifications ■ Different specifications of trays can be created by varying thickness ■ Forming with different materials using the same mold is also possible ■ Securely fix and hold parts with vacuum tray dividers tailored to the shape of the parts *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

At Sato Pack, we are capable of vacuum forming "component trays." To protect components during transportation between factories, such as electronic and automotive parts, we propose and design solutions that securely hold the components in place. By selecting materials according to the characteristics and requirements of the target components, we customize trays with high functionality. 【Features】 ■ Customizable trays with high functionality ■ Material selection based on specifications allows for changes in tray functionality ■ Different specifications of trays can be created by varying thickness ■ Molding with different materials using the same mold is also possible ■ Vacuum tray dividers tailored to the shape of the components ensure secure fixation and retention *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

A "blister pack" is a transparent package made by molding plastic, used to protect various items such as plastic models, children's toys, daily goods, cosmetics, and adhesives (glue). The reason for its transparency is to allow buyers to see and choose the product. It can be categorized into three main types based on the packaging method between the product and the backing (printed material that specifies the product's specifications, etc.). [Features] - Transparent package made by molding plastic - Made from durable plastic, resistant to water, dirt, and dust - The visibility of the contents provides reassurance for buyers - Can be easily shaped according to the items placed inside - Manufacturing costs are lower compared to bottling or boxing *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

When it comes to "vacuum forming," many people may think of packaging materials such as component trays and blister packs, but a wide range of industrial parts and products are also produced using vacuum forming. Items that were thought to be only manufacturable through injection molding, which requires expensive molds, can sometimes be made with vacuum forming using low-cost molds. Additionally, taking advantage of the ability to mold thermoplastic resin sheets into various shapes, it is also utilized for product protection covers, manufacturing auxiliary parts in industrial processes, and manufacturing jigs. 【Features】 ■ Suitable for small lot and diverse production ■ Excels in large and thin-walled molding ■ Material selection for molds is possible ■ Easy selection of materials *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

Our company specializes in the injection molding of thermoplastic elastomer resins. These resins, which possess the elasticity of rubber—thermoplastic elastomers (TPE)—are molded and utilized in products such as seals and cushions, taking advantage of rubber's properties. The manufacturing process can be streamlined, resulting in high cost performance, and replacing rubber parts with elastomer molded products can lead to cost reductions. [Features] - Resin molded products that utilize the properties of rubber - Used in seals, cushions, etc. - Generally reduces processes compared to rubber manufacturing - Cost reduction by replacing rubber parts with elastomer molded products - Hardness can be adjusted to meet specifications *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We provide consultation and examination of suitable materials such as gaskets, cushions, and vibration-damping materials as various auxiliary components. We propose suitable materials that match the physical properties and characteristics of various materials such as polyethylene foam, rubber sheets, and polyurethane foam with the specifications required by our customers. We will suggest the final shape considering assembly efficiency, processability, and mass production. 【Processing Examples (Partial Excerpt)】 ■ Die-cut products made from sheets of polyethylene foam bonded with double-sided tape ■ Die-cut products made from EPT sponge (synthetic rubber) (Application: gasket) ■ Die-cut products made from PP (polypropylene) sheets ■ Die-cut products made from 0.3t polyethylene sheets ■ Half-cut products of Opcell (continuous bubble polyethylene foam) with washi adhesive *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Other contract services

A blister pack is used as packaging for various products (electrical appliances, cosmetics, daily necessities). Since it is required to be transparent so that the contents are clearly visible, it is usually vacuum-formed using PET (Polyethylene terephthalate). Blister packs can be broadly categorized into three types based on the packaging method with the product and backing paper (printed material that specifies product details): bend type, seal type, and shell pack type. 【Lineup】 ■ Bend Type - A type where the backing paper is slid into a blister pack that has been thermally bent on two sides and the bottom. ■ Seal Type - A type where the backing paper and blister pack are sealed together by thermal bonding. ■ Shell Pack Type - A type where both the front and back are made of blister pack, covering the product with blister packs on both sides. *For more details, please refer to the PDF document or feel free to contact us.

• plastic
• Plastic Mould
• Contract manufacturing

Expanded polystyrene is actively used not only as packaging material but also for various applications as industrial components. At our company, instead of molding with molds, we can cut sheets of expanded polystyrene and create various shapes through adhesive bonding. Additionally, we also offer expanded polypropylene made from polypropylene beads. Please feel free to contact us if you have any requests. 【Features】 ■ Active use in various applications as packaging material and industrial components ■ Capable of producing various shapes ■ Expanded polypropylene is also available *For more details, please refer to the PDF document or feel free to contact us.

• plastic
• Processing Contract

Our company specializes in the processing and sales of plastic (pressure forming) molding. With vacuum forming, we can change the functionality of trays by selecting materials according to the required specifications from various materials. Additionally, we can create trays with different specifications not only by changing the material itself but also by varying the thickness. Please feel free to contact us with your requests. 【Features】 ■ Suitable for small lot and diverse production ■ Proficient in large and thin molding ■ Material selection for molds is available ■ Easy material selection *For more details, please download the PDF or feel free to contact us.

• plastic
• Plastic Mould