[Case Study] Resolved by Changing the Molding Method! Internal Air Defect
This is an example of improvement due to a change in the manufacturing method of urethane parts used in fluid control equipment. Traditionally, urethane was cast-molded to create blocks, which were then subjected to machining. However, since the air (bubbles) inside the product generated during the casting process could not be detected until machining was performed, defects were discovered after processing, resulting in losses of materials and processing man-hours. Therefore, the manufacturing method was changed from cast molding to press molding. This suppressed the generation of internal air and implemented dimensional adjustments using molds. This resulted in improved yield and reduced manufacturing costs.
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Purpose: Urethane parts for fluid control equipment Conventional manufacturing method: Injection molding + machining Changed manufacturing method: Press molding Main improvements: Reduction of internal air, improved yield Effects: Reduction of material and processing loss, reduced manufacturing costs
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Applications/Examples of results
Urethane Parts for Fluid Control Equipment In urethane parts used for fluid control, if air remains inside, it can be discovered as bubbles or defects after machining, leading to defects. In this case, by changing the manufacturing method from conventional casting to press molding, we reduced the air inside the urethane. This helped suppress defects caused by internal flaws that were previously discovered after machining, resulting in improved yield and reduced manufacturing costs. We propose a review of the manufacturing process, including molding methods and machining methods, according to product shape and required specifications. With multiple molding methods available, we can address manufacturing challenges for urethane parts, such as "internal defects that cannot be identified until machining" and "poor yield."
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Since our establishment in 1973, we have specialized in industrial urethane rubber, consistently producing everything from manufacturing to processing. Thanks to the tremendous support and guidance from all of you, we have developed into a company that now produces over 300 tons of urethane rubber products annually. We are committed to continuously working on the development of urethane rubber products and aim to be a leading company that can respond to the needs of the times.
