Eliminate the labor of assembly and welding! Special blow molds achieve significant cost reduction through "integrated parts."
Are you struggling with the assembly and welding processes of multiple parts in the manufacturing of plastic hollow products? The "integrated parts proposal using special blow molds" from Nakajo Seisakusho will solve that challenge! Typically, components like flanges and nuts are separately manufactured through injection molding and then welded and assembled later. However, with our special blow molds, we can perform "insert molding" by setting metal nuts or other components into the mold before shaping, as well as "complete integrated molding" that includes the flange section. ■ Benefits of Implementation - Significant reduction in costs and labor: The need for post-process assembly and welding work is eliminated, cutting out the costs of dedicated equipment and jigs such as welding machines. - Improved quality and aesthetics: Avoids misalignment and strength reduction from welding, as well as the risk of liquid leakage. Since there are no burrs at the joints, the appearance of the product is also beautifully finished. With our unique mold design know-how utilizing a "slide mechanism," we can accommodate high-difficulty requests such as simultaneously placing multiple insert parts. For design aimed at cost reduction, trust Nakajo Seisakusho!
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【Applicable Manufacturing Methods】 Direct blow molding, 3D blow molding, multilayer blow molding 【Parts Compatible with Inserts】 Metal nuts, metal pipes, various injection molded products (such as flanges and clips) *Thanks to our unique "slide mechanism" design, we can accommodate simultaneous insertion of multiple parts and insertion into undercut shapes that are difficult to release. 【Applicable Product Sizes】 A wide range from palm-sized small parts to large products exceeding 1,000mm in length (such as long air ducts). 【Applicable Product Materials (Plastics)】 Various resin materials suitable for applications, including PP, PE (HDPE, LDPE), ABS, PA (nylon with glass fiber), TPO (thermoplastic elastomer), and EVOH (multilayer barrier material). 【Applicable Mold Materials】 Aluminum, ZAS (zinc alloy), S55C (carbon steel) *We propose the optimal mold material based on your budget and production lot size, from prototypes to mass production. 【Main Mold Processing Equipment】 Large 5-axis control machining centers (such as D800Z), high-precision 5-axis control machining centers (such as Vertex550-5X), and others.
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**Main Uses and Target Industries** It is utilized in a wide range of industries such as automotive and trucks, construction machinery, agricultural machinery, and medical and nursing equipment, where there are processes for attaching (assembling or welding) separate parts to hollow products. **Examples of Integration Achievements and Problem-Solving** ■ Automotive Flanged Duct (Elimination of Welding) The pipe body and the injection-molded flange, which were previously made separately and welded, are fully integrated through blow molding. This eliminated the welding process, preventing misalignment, liquid leakage risks, and burr formation, thereby improving quality. ■ Agricultural Drone Chemical Tank (Multiple Inserts) In the highly durable tank required for drones, nine insert parts were simultaneously integrated and molded using a sliding mechanism. This significantly reduced the complex assembly work. ■ Automotive Air Duct (Integration of Irregular Inserts) Three types of components, including two types of clips and a pipe-shaped part, were integrated. Accurate positioning allows for the molding of complex ducts without any subsequent processes. ■ Elimination of Insert Parts through Pressing By innovating the mold design, protrusions such as brackets were pressed within the mold, eliminating the need for insert parts and reducing costs.
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Your Consultative Partner for 3D Blow Molds—From Concept to Reality Based in Edogawa, Tokyo, Chuetsu Seisakusho Co., Ltd. is here to solve your engineering challenges. Whether you're wondering, "Can this complex hollow shape be made of plastic?" or "How can we replace metal parts with plastic to reduce weight?", we have the answers. 3 Reasons to Choose Chuetsu Seisakusho: 1. Unrivaled 3D Blow Molding Technology From complex automotive air ducts to daily-use bottles, we design and manufacture molds that directly contribute to your product's weight reduction and cost savings. 2. Upstream Proposals to Prevent Defects We don't just build exactly what is on the drawing. We offer professional VA/VE (Value Analysis/Value Engineering) proposals to optimize your product's shape and prevent mass-production issues, such as suggesting design tweaks to avoid wall thinning. 3. Crystal-Clear Explanations Powered by AI Mold engineering can be highly technical, but we make it easy to understand. Utilizing the latest AI tools, we provide visual and intuitive explanations of complex mold structures and molding processes. We welcome your inquiries, even if you only have a rough sketch or an early-stage idea. Let's make it happen together. Contact us today!
