Integrated molding of an unusual tubular shape (kamaboko shape)! We launched production from the start of construction in just 60 days.
The customer manufactures and sells OA equipment and was considering a non-cylindrical, oval shape for product development to increase filling capacity. However, it was anticipated that the oval shape would have greater release resistance compared to the cylindrical shape. In this product, by creating a mold with a unified cylindrical shape that does not require division, we aimed to significantly reduce the costs associated with mold production and product costs. With an overall length of approximately 510mm and a draft angle of 0.1°, it would be difficult to extract such a long product using a sliding structure in traditional molds. Therefore, we reduced the draft angle and developed a sliding core operation method and cooling structure to alleviate the sliding core's impact on the product, which became a key point in mold production. [Challenges and Considerations in Product Development] - Consideration of an oval shape instead of a cylindrical shape to increase filling capacity - Anticipation that the oval shape would have greater release resistance compared to the cylindrical shape - Due to the expectation that high release resistance would prevent the product from being extracted from the mold, a proposal was considered to divide the different cylindrical shapes and join them through welding - Exploration for ideas to realize products other than the two-part proposal for the different cylindrical shape *For more details, please refer to the PDF document or feel free to contact us.*
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[After Proposal] - By manufacturing the mold without dividing it into two parts and maintaining a unified cylindrical shape, we achieved a significant reduction in both mold production costs and product costs. - The product, which is 510mm in total length, has a hollow interior. Increasing the slope makes it easier to release, but it causes a difference in wall thickness at both ends of the product, leading to shrinkage and decreased productivity. - Generally, a slope of 1° is designed, but by minimizing the slope as much as possible, we reduced the difference in wall thickness and achieved a product with a large volume and minimal shrinkage. - We established a mold in the 450t class from the start of construction to mass production within 60 days. *For more details, please refer to the PDF document or feel free to contact us.*
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For more details, please refer to the PDF document or feel free to contact us.
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Company information
Sangyo Composite Resin is a plastic injection molding manufacturer. Based on the molding know-how and infrastructure cultivated over many years, we continue to provide plastic parts to customers in a wide range of industrial sectors. ■ Supporting manufacturing with "comprehensive strength" 1. 82 electric injection molding machines (clamping force 50–650t, product weight 0.05–3500g) 2. Automated logistics warehouse with 3000 pallets 3. Human resource education (65 nationally certified molding technicians) 4. Molding technology and know-how (capable of handling general-purpose resins to super engineering plastics) 5. Management system certified with ISO9001 and ISO14001, and ISO13485 (with applicable scope) 6. Traceability (introduction of a production management system specialized for injection molding to track the routes of products, parts, and raw materials) ★★★ Announcement ★★★ We will be exhibiting at the 30th Mechanical Components Technology Exhibition (M-tech) from July 9 to 11, 2025. For more details, please check the news or announcements on our company website.