The thickness has been reduced to 0.5mm through machining, and surface grinding is also possible. Since it is machined, the dimensional accuracy is much higher than that achieved by manufacturing with molds.
We have made porous (sintered) metal as thin as possible. In the porous (sintered) metal industry, machining has been considered taboo because it causes clogging and prevents the material from functioning as a filter. However, manufacturing with molds has been extremely difficult, and we felt the limitations of porous (sintered) metal. With this technology, the walls of the porous (sintered) metal have been removed, allowing for the production of shapes that were impossible with molds.
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When machining is applied to porous (porous) sintered metals, various advantages arise. First is the issue of precision. Typically, porous sintered metals expand and contract when heated to high temperatures, making it difficult to achieve dimensional accuracy; however, machining significantly improves dimensional precision. Next is the issue of shape. In the case of stainless steel (SUS) porous sintered metals, pressure forming is also performed, which worsens the conditions further, but the shape is determined by the upper and lower punches, so shapes like a T-shape (cheese) cannot be made. However, if machining is possible, this can be overcome. *However, not everything can be machined; it is limited to those that can be chucked, as it is still a porous (porous) body... If the chucking force is too weak, the material may fly off during processing, and conversely, if it is too strong, it can reduce the voids, which is the greatest characteristic of porous (porous) sintered metals, leading to problems.
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We have tried to make porous sintered metal as thin as possible. In the porous sintered metal industry, machining has been considered taboo because it causes clogging and prevents the material from functioning as a filter. However, manufacturing with molds has proven to be extremely difficult, and we felt the limitations of porous sintered metal. With this technology, the walls of the porous sintered metal have been removed, allowing for the production of shapes that were impossible with molds.
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Products made using the powder metallurgy method (a process of shaping metal powder and sintering it to create metal products) are referred to as "sintered metals." Among these, by specializing in sintered metal filters, which are porous metals, we can offer tailored solutions for various applications. Examples of applications include filters (for filtration and separation), silencers (for noise reduction), fluid rectification, liquid absorption, bubbling, and explosion-proof filters (frame arresters), and we are currently developing more applications. Additionally, over 15 types of materials can undergo sintering treatment. There are many types of porous metals, and not only pore diameter but also pore structure affects performance. Our distinguishing feature is that our sintered metal filters, made from metal powder, are all open-pore/continuous-pore (open porous) porous metals. Other types of porous metals include sintered metal mesh, which is created by stacking metal wire and sintering it while maintaining the precision of the mesh opening and also possessing strength; sponge-like porous metals formed solely from a skeletal structure; porous metals with numerous straight holes that resemble lotus roots; and foamed metals that have countless closed pores/independent pores (closed pore) created by adding a foaming agent to molten metal. Each type of porous metal has its own advantages and disadvantages, making it necessary to select the appropriate porous metal based on the intended application.