Integrated design for quality improvement and cost reduction in the semiconductor industry.
Combining complex split structures into one casting. A thorough explanation of the benefits of "integrated molding" that dramatically reduces assembly labor and its differences from other methods.
In high-precision semiconductor manufacturing processes, many complex structural components such as piping and brackets are used. Traditionally, these have been joined using a "split structure" involving multiple parts welded or bolted together, which presents challenges such as "variability in precision" and "manufacturing labor." The solution to this is Hinode's "integrated molding through casting." ■ Benefits of Integration - Reliability: Eliminates joints, minimizing the risk of leaks. - Cost: Significantly reduces welding assembly and individual part processing steps. - High Precision: Integrated molding resolves misalignment caused by cumulative tolerances between parts. ■ Comparison of Methods and Selection Points - Welding: Suitable for prototypes, but quality variability and labor are issues during mass production. - Integrated Casting: Offers overwhelming advantages in total cost and reliability during mass production. The Hinode Group provides consistent support from material proposals to shape optimization design, contributing to the enhancement of equipment value.
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basic information
The Hinode Group provides one-stop solutions for your manufacturing challenges from the development stage to mass production through "performance improvement by optimizing materials and structures" and "a consistent production system with diverse materials and processes." 【We solve the following issues】 ● For those considering "vibration reduction," "thermal change reduction," "high rigidity," and "lightweight" for their equipment: - We propose solutions unique to foundry manufacturers through proprietary materials and structural analysis/topology optimization. - We also have a robust 3D printing and prototype inspection system to shorten development time. ● For those struggling with the ordering process and lead times for cast parts: - We accommodate a variety of materials and manufacturing processes, including cast iron, cast steel, aluminum, and special materials. - We provide one-stop support from mold making and prototyping to casting, processing, assembly, and transportation. ● For those considering stable supply of castings: - We have a proven track record as a top share manufacturer of manhole covers with 100 years of history. - We have experience with over 350 customers in the industrial machinery sector, including machine tools, industrial robots, automobiles, and semiconductor manufacturing equipment. - Our group structure can handle a wide range from small lots of various types to large lots of thousands of units. - We have a cooperative network of over 400 partner companies both domestically and internationally, capable of accommodating any material or size.
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Applications/Examples of results
Semiconductor manufacturing equipment and electronic component manufacturing equipment (frames, bases, chambers, vacuum pumps, precision parts made of low thermal expansion cast iron, etc.) Machine tools (beds, columns, beams made of cast iron and mineral casting) Industrial robots (bases, casings, arms) Transport equipment and construction machinery (engines, drive systems, hydraulic parts, undercarriage parts) Shipbuilding and marine equipment (sheaves, casings)
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Company information
Hinode Holdings is a professional casting group comprising experts in cast iron, cast steel, aluminum casting, machining, and logistics. Using the collective strength of our group, we solve challenges across design, development, production, and procurement, such as "weight reduction and vibration suppression of equipment parts," "precision machining," and "complexities in supplier management and ordering." From the development stage of equipment to VA/VE for mass-produced machines, leave it to Hinode. ■ Target Industries Semiconductor and electronic component manufacturing equipment (Frames, bases, chambers, vacuum pumps, precision parts made of low thermal expansion cast iron, etc.) Machine tools (Beds, columns, and beams made of cast iron or mineral casting) Industrial robots (Bases, casings, and arms) Transportation equipment and construction machinery (Engines, drivetrains, hydraulic parts, and undercarriage components) Shipbuilding and marine equipment (Sheaves, casings) ■ Target Processes / Materials Processes: Material development & selection, structural design, prototyping, mass production, machining, assembly, quality control, global procurement, and domestic/international logistics. Materials: Cast iron (FC/FCD), aluminum casting, cast steel, stainless cast steel, low thermal expansion materials, heat-resistant cast steel, wear-resistant materials, mineral casting, and others.
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